Lock body

Abstract

Disclosed herein is a lock assembly comprising a cartridge housing containing a bolt having a retracted position and an extended position in which the bolt extends out of the cartridge housing; a motor module comprising a motor; and a locking member operatively connected to the motor, the motor operable to drive the locking slide between a first position and a second position, wherein in the first position the locking member does not prevent the bolt from being moved from the extended position to the retracted position, and in the second position the locking member prevents the bolt from being moved from the extended position to the retracted position.

Description

LOCK BODYField

[0001] The invention relates to lock assemblies, and in particular, lock assemblies that are useful in multipoint lock assemblies and as standalone locks.Background

[0002] Motorised lock assemblies having motors mounted within the escutcheon of the lock assembly are known. These escutcheons are typically relatively large since they need to house the motor as well as supporting components such as batteries, printed circuit boards, wiring, and mechanical components which interact with the motor. These locks generally employ clutched systems where a user operated lever (such as a door handle) is engaged and disengaged by the motor to allow and disallow retraction of a bolt in the lock assembly on rotation of the user operated lever.

[0003] Typically, these lock designs use a mechanical cylinder override mechanism to enable a user to actuate the bolt via lever in the case that the batteries are flat or there is an electronic malfunction. Upon operation of a cylinder mounted in the escutcheon, a mechanism attached to the rear of the cylinder actuates a motor slide in the motor module from the locked position to the unlocked position. Actuation of this motor slide re-engages the user operated lever with the bolt to allow a user to actuate the lever to retract the bolt. That is, to open a door, the user operates the mechanical override cylinder (such as via insertion and turning of a key) and holds the override cylinder in the actuated position whilst then rotating the user actuated lever to retract the bolt and open the door.

[0004] When the user actuated lever is returned to the neutral position and the cylinder moved back to the neutral position (e.g., by withdrawal of a key), the motor slide moves back to the locked position and the user operated levers are returned to their disengaged state with the bolt.

[0005] One downside of this arrangement is that with this arrangement of the motor modules in the escutcheon, the levers are typically clutched. This means that when the lock assembly is locked, the user actuated levers can still be rotated but without retraction of the bolt. This can beconfusing for users as typically / traditionally when a lock is locked, the user actuated lever either does not rotate or does not rotate very far.

[0006] Another downside of this arrangement is that lock assemblies required deadlocking capability are expensive since these require two motor assemblies. Deadlocking is when both sides of the door are locked and require an electronic credential or a cylinder key from either side of the door to operate the lock / open the door. To deadlock a lock assembly with the motor module in the escutcheon, two motor modules are required, one in the exterior escutcheon and one in the interior escutcheon. Such locks can also be complicated and / or cumbersome to install.

[0007] Another disadvantage of this arrangement is that lock designs that utilize clutched lever designs are prone to manipulation and forced attacks. The clutch needs to be carefully designed to avoid the possibility of intruders manipulating the lever in a way that binds the clutch components allowing entry to a locked door. This can add complexity to the lock design.

[0008] It is an object of the invention to address at least one shortcoming of the prior art and / or provide a useful alternative.

[0009] Reference to any prior art in the specification is not an acknowledgment or suggestion that this prior art forms part of the common general knowledge in any jurisdiction or that this prior art could reasonably be expected to be understood, regarded as relevant, and / or combined with other pieces of prior art by a skilled person in the art.Summary of Invention

[0010] In one aspect of the invention, there is provided a lock assembly comprising: a cartridge housing containing: a bolt having a retracted position and an extended position in which the bolt extends out of the cartridge housing; a motor module comprising a motor; and a locking member operatively connected to the motor, the motor operable to drive the locking member between a first position and a second position, wherein: in the first position the locking member does not prevent the bolt from being moved from the extended position to the retracted position, andin the second position the locking member prevents the bolt from being moved from the extended position to the retracted position.

[0011] In an embodiment, in the first position the locking member is operatively disengaged from the bolt.

[0012] In an embodiment, in the second position the locking member is operatively engaged with the bolt when the bolt is in the extended position to prevent the bolt from being moved from the extended position to the retracted position. The locking member may be directly engaged with the bolt or indirectly engaged with the bolt, such as via an intermediary e.g., an actuator assembly or the like.]

[0013] In an embodiment, the cartridge housing further contains a manually actuatable override having a rest position and an override position, the manually actuatable override engaged with, or engageable with, the locking member on movement from its rest position to its override position to move the locking member from its second position to its first position.

[0014] In one form of the above embodiment, the manually actuatable override is configured to move from its rest position to its override position on application of a force thereto. Preferably, the force is a user applied force.

[0015] In one form of the above embodiment, the bolt is actuatable from its extended position to its retracted position while the manually actuatable override is held by application of the force in its override position.

[0016] In one form of the above embodiment, the manually actuatable override is configured to move the locking member from the second position to the first position against a spring bias, the force being sufficient to overcome the spring bias. Preferably, the spring bias is provided by a spring housed within the motor module.

[0017] In one form of the above embodiment, on release of the force, the spring bias is configured to move the locking member from the first position to the second position.

[0018] In various forms of the above embodiments, the manually actuatable override comprises: an input portion mechanically displaceable by a user over a first length, andan output portion operatively engaged with the input portion and the locking member, the output portion being displaceable over a second length when the input portion is displaced the first length to move the locking member from the second position to the first position; and wherein the second length is greater than the first length.

[0019] By way of example, the manually actuatable override is in the form of a pivot lever having a first arm defining the input portion and a second arm defining the output portion, the first arm and second arm extending from a pivot, wherein the second arm is longer than the first arm. In this way, a small displacement of the input portion, such as by actuation of a key cylinder or the like, results in a relatively larger displacement of the output portion.

[0020] In an embodiment, the motor module further contains a motor drive mechanism, the motor drive mechanism operatively connected to the motor, the motor drive mechanism configured to convert rotational motion of the motor into linear motion to drive the locking member between the first position and the second position.

[0021] In an embodiment, the locking member is a locking slide. Preferably, the locking slide is linearly slidable between its first position and its second position.

[0022] In one form of the above embodiment, the motor drive mechanism comprises: a motor driven shaft; and a support engaged with the motor driven shaft such that rotation of the driven shaft causes linear movement of the support in an axial direction along the driven shaft between an unlocked position corresponding to the first position of the locking member and a locked position corresponding to the second position of the locking member.

[0023] In an arrangement, the motor comprises a drive shaft coupled to the driven shaft, such that rotary motion from the motor is transferred from the drive shaft to the driven shaft.

[0024] In an arrangement, the driven shaft and support are operatively connected via a spring.

[0025] It is preferred that the support is configured to translate along a longitudinal axis of the driven shaft in response to compression of the spring. More preferably, the spring is a helical compression spring. Still further, it is preferred that the helical compression spring is configuredto spring bias the locking member to its second position when the support is in its locked position.

[0026] In forms of the above embodiment, the cartridge housing further contains a manually actuatable override having a rest position and an override position, and wherein on moving the manually actuatable override from the rest position to the override position, the support is moved relative to the driven shaft to the unlocked position against a spring bias of the spring.

[0027] In one such arrangement, the manually actuatable override comprises: an input portion mechanically displaceable by a user over a first length, and an output portion operatively engaged with the input portion and the locking member, the output portion being displaceable over a second length when the input portion is displaced the first length to move the locking member from the second position to the first position; and wherein the second length is greater than the first length.

[0028] In arrangements of the above embodiment comprising a spring and in which the spring is a helical compression spring, it is preferred that the spring comprises a helical body in threaded engagement with a at least one projection on the driven shaft such that rotation of the driven shaft causes linear movement of the spring along a longitudinal axis of the driven shaft.Additionally or alternatively, it is preferred that, the support is carried by the spring.

[0029] In an embodiment, the cartridge housing further contains one or more sensors configured to detect if the locking member is in the first position and / or in the second position.

[0030] In various forms of the above embodiments, the cartridge housing further contains one or more sensors configured to detect if the support is in the first position and / or in the second position. It is preferred that the one or more sensors are located in the motor module.

[0031] In one or more arrangements, the support comprises a tab, and the one or more sensors are configured to detect a position of the tab. In a preferred arrangement, the tab comprises a permanent magnet, and the one or more sensors are Hall effect sensors and / or magnetic sensors.

[0032] In an embodiment, the cartridge housing further contains: a spindle cam having a spindle passage for receiving a spindle therethrough; andwherein the spindle cam is rotatable by a user from a rest position to an actuated position to actuate the bolt from the extended position to the retracted position.

[0033] In one form of the above embodiment: when the locking member is in the first position, the spindle cam is rotatable by a user from a rest position to an actuated position to actuate the bolt from the extended position to the retracted position; and when the locking member is in the second position, the spindle cam is locked from rotation into the actuated position.

[0034] In an embodiment, the lock assembly further comprises a user actuatable release mechanism which, when actuated by a user, generates an electronic control signal to operate the motor to move the locking member from the second position to the first position.

[0035] By way of example, the user actuated release mechanism may be in the form of a push button on an escutcheon or a handle configured for installation on an interior facing side of a door, or a remote electronic device such as a mobile phone or the like.

[0036] In one form of the above embodiments, the lock assembly is operable in: a passage mode, wherein the locking member is in the first position and the spindle cam is rotatable by a user to actuate the bolt from the extended position to the retracted position; and a privacy mode, wherein the locking member is in the second position and is movable into the first position on actuation of the user actuatable release mechanism.

[0037] In an embodiment, the lock assembly is operable in a deadlocked mode, wherein the locking member is in the second position and cannot be actuated by operation of the user actuatable release mechanism.

[0038] In one form of the above embodiments, the cartridge housing further contains a main slide, the spindle cam configured to move the main slide from a first main slide position to a second main slide position on rotation of the spindle cam from its rest position to its actuated position. It is preferred that when the locking member is in the second position, the main slide cannot be moved into the second main slide position. Additionally or alternatively, it is preferred that the main slide comprises coupling structure for operative connection to one or more remote latches.

[0039] In one form of the above embodiments, the user actuatable electronic release mechanism comprises a processor configured to receive a user input signal to generate the electronic control signal.

[0040] In an embodiment, when the locking member is in the second position and the bolt is in the extended position, the locking member engages with a first shoulder on the bolt to prevent the bolt from being moved from the extended position to the retracted position. In one form of this embodiment, when the bolt is in the retracted position, the locking member can be in the first position or the second position or an intermediate position between the first position and the second position. In another form of this embodiment, when the locking member is in the second position and the bolt is in the retracted position, the locking member engages with a second shoulder on the bolt.

[0041] In an embodiment, when the locking member is in the second position and the bolt is in the extended position, the locking member projects into a first recess in the bolt to prevent the bolt from being moved from the extended position to the retracted position. In one form of this embodiment, when the locking member is in the second position and the bolt is in the retracted position, the locking member projects into a second recess in the bolt.

[0042] In a preferred arrangement thereof, the bolt comprises a cam surface configured to push the locking member towards its first position on movement of the bolt from its retracted position towards its extended position. More preferably, the cam surface pushes the locking member against a spring bias. Still more preferably, when the bolt is moved into the extended position, the locking member is configured to be moved to the second position and into, or into the proximity of, the first shoulder by the spring bias

[0043] In an embodiment, the lock assembly further comprises a sensor configured to detect whether a door that the lock assembly is installed on is open or closed.

[0044] In an embodiment, the locking member comprises an elongate body formed from plastic.]

[0045] In an embodiment, the locking member further comprises a tip formed from metal, the tip configured to engage one or more components within the cartridge when in the secondposition to prevent the bolt from being moved from the extended position to the retracted position. It is preferred that the tip is separable from the elongate body.

[0046] In an embodiment, the cartridge has a thickness of 16 mm or less.

[0047] In an embodiment, the lock assembly further comprises a user actuatable key cylinder, the key cylinder having an engagement structure engaged with, or engageable with, a or the manually actuatable override; wherein on actuation by a user, the key cylinder is configured to apply a or the force to the manually actuatable override to move the manually actuatable override from a or the rest position to an or the override position.

[0048] In one form of the above embodiment, the cartridge housing comprises an opening through which the engagement structure engages with, or is engageable with, the manually actuatable override.

[0049] In one arrangement thereof, the engagement structure projects through the opening and into the cartridge housing to engage with, or be engageable with, the manually actuatable override. In an alternative arrangement, the manually actuatable override comprises a projection that extends through the opening and out of the cartridge housing to engage with, or to be engageable with, the engagement structure.

[0050] It is preferred that, on actuation, the key cylinder is configured to move the engagement structure longitudinally.

[0051] For avoidance of doubt, the key cylinder is actuatable on operation of a correctly coded key inserted therein.

[0052] In one form of the above embodiment, the manually actuatable override comprises: an input portion mechanically displaceable by a user, and an output portion operatively engaged with the input portion and the locking member, the output portion being displaceable on displacement of the input portion to move the locking member from the second position to the first position.

[0053] In one arrangement thereof, the engagement structure is engaged with, or is engageable with the input portion to displace the input portion and thereby move the manually actuatable override from its rest position to its override position.

[0054] In one arrangement thereof: the input portion is displaceable over a first length, and the output portion is displaceable over a second length; and wherein the second length is greater than the first length.

[0055] In one form of the above embodiment, the key cylinder comprises: a housing having a passage defining a longitudinal axis; a barrel comprising: an exterior facing end having a key slot for insertion of a key in a key insertion direction generally along or aligned with the longitudinal axis; and an interior facing end having an engagement structure for engagement with the actuator of the manual override mechanism; wherein the barrel is mounted within the housing, and on location of a correctly coded key within the key slot and, on application of a force thereto, is operable from a rest position to an engaged position to longitudinally move the engagement structure from its rest position to its override position.

[0056] In one form of the above embodiment, the engagement structure is an engagement pin.

[0057] In one arrangement, the engagement pin is configured to project through an opening in the cartridge housing for engagement with the manually actuatable override.

[0058] In one arrangement, the engagement pin has an adaptable length along a pin axis thereof.

[0059] It is preferred that the engagement pin comprises a first pin portion and a second pin portion, the second pin portion being mounted to the first pin portion, the first pin portion and the second pin portion being movable relative to one another in a direction along the pin axis between a contracted state and an elongated state.

[0060] It is further preferred that the first pin portion and the second pin portion are spring biased to the elongated state.

[0061] In one arrangement, the first pin portion is a shaft and the second pin portion is a sheath, the sheath being slidably and coaxially mounted to the shaft.

[0062] In one form of the embodiments generally described above, the key cylinder is mounted within an escutcheon.

[0063] In one form of the embodiments generally described above, the key cylinder is a rotational key cylinder or a push key cylinder.

[0064] As used herein, except where the context requires otherwise, the term "comprise" and variations of the term, such as "comprising", "comprises" and "comprised", are not intended to exclude further additives, components, integers or steps.Brief Description of Drawings

[0065] Further aspects of the present invention and further embodiments of the aspects described in the preceding paragraphs will become apparent from the following description, given by way of example and with reference to the accompanying drawings.

[0066] Figure 1 is an exploded perspective view of a lock system including a lock assembly in accordance with one embodiment of the invention for installation into a door frame. In this embodiment, the lock assembly is illustrated as a central lock assembly in a multipoint lock system. However, the skilled person will appreciate that the lock assembly may be used as a standalone lock assembly.

[0067] Figure 2 is a perspective view illustrating the lock system of Figure 1 installed on door frame in a door closed position.

[0068] Figure 3 is a perspective view illustrating lock system of Figure 1 showing the arrangement of central lock assembly, upper and lower multipoint lock assemblies and connecting drive rod.

[0069] Figure 4 is an exploded perspective view of the central lock assembly of the lock system of Figure 1 from a first side thereof.

[0070] Figure 5 is an exploded perspective view of the central lock assembly of the lock system of Figure 1 from a second side thereof.

[0071] Figure 6 is an internal view of the central lock assembly of the lock system of Figure 1 in the door closed position.

[0072] Figure 7 is an internal view of the central lock assembly of the lock system of Figure 1 in the door open position.

[0073] Figure 8 is a perspective view of the rear of the central lock assembly of the lock system of Figure 1.

[0074] Figure 9 is a perspective view of a motor module which may be used, for example, with the lock assembly of Figure 1.

[0075] Figure 10 is a top-down plan view of the motor module of Figure 9.

[0076] Figure 11 is an exploded view of the motor module of Figure 9 from a first side thereof.

[0077] Figure 12 is an exploded view of the motor module of Figure 9 from a second side thereof.

[0078] Figure 13 is an internal view of the motor module of Figure 9 in an unlocked state.

[0079] Figure 14 is an internal view of the motor module of Figure 9 in a locked state.

[0080] Figure 15 is an internal view of the motor module of Figure 9 in an override state.

[0081] Figure 16 is an internal view of the central lock assembly of the lock system of Figure 1 showing the arrangement of components when lock assembly is an unlocked operating state with retractable bolt in the extended position, e.g., in passage mode / door closed.

[0082] Figure 17 is an internal view of the central lock assembly of the lock system of Figure 1 showing the arrangement of components when a user actuates the lock assembly from the unlocked operating state of Figure 16 to a door open position.

[0083] Figure 18 is an internal view of the central lock assembly of the lock system of Figure 1 showing the arrangement of components after a user has released a handle upon placing the lock in the door open position of Figure 17.

[0084] Figure 19 is an internal view of the central lock assembly of the lock system of Figure 1 showing the arrangement of components when lock assembly is in a privacy or deadlocked mode and the door is in the closed position.

[0085] Figure 20 is an internal view of the central lock assembly of the lock system of Figure 1 showing the arrangement of components when lock assembly is in a privacy or deadlocked mode and the door is in the closed position after actuation of the door handle.

[0086] Figure 21 is an internal view of the central lock assembly of the lock system of Figure 1 showing the arrangement of components when the manually actuated lock slide override arm is actuated.

[0087] Figure 22 is an internal view of the central lock assembly of the lock system of Figure 1 showing the arrangement of components when a user actuates the lock assembly to move the door into the open position whilst the override is active as illustrated in Figure 21.

[0088] Figure 23 illustrates a multipoint lock assembly of the lock system of Figure 1 in the unlocked, closed door state.

[0089] Figure 24 illustrates a multipoint lock assembly of the lock system of Figure 1 in an actuated unlocked, open door state.

[0090] Figure 25 illustrates a multipoint lock assembly of the lock system of Figure 1 in an unlocked, open door state.

[0091] Figure 26 illustrates a multipoint lock assembly of the lock system of Figure 1 in the deadlocked or privacy locked, closed door state.

[0092] Figure 27 illustrates a multipoint lock assembly of the lock system of Figure 1 in the deadlocked or privacy locked, closed door state after actuation of the door handle.

[0093] Figure 28 is an illustration of a lock assembly of Figure 1 installed within a door frame.

[0094] Figure 29 is a partial perspective view of a lock assembly showing detail of the bolt in the retracted position.

[0095] Figure 30 is a partial perspective view of a lock assembly showing detail of the bolt on movement from the retracted position to the extended position.

[0096] Figure 31 is a partial perspective view of a lock assembly showing detail of the bolt in the extended position.

[0097] Figure 32 is an exploded perspective view of a key cylinder override actuator.

[0098] Figure 33 is a perspective view of the key cylinder of Figure 32 showing the override pin in the expanded state.

[0099] Figure 34 is a perspective view of the key cylinder of Figure 32 showing the override pin in the contracted state.

[0100] Figure 35 is a partial perspective view of an escutcheon showing the override pin in its disengaged position.

[0101] Figure 36 is a partial perspective view of an escutcheon showing the override pin in its engaged position.Description of Embodiments

[0102] The invention will be described below in relation to one or more embodiments thereof.

[0103] Figure 1 is an exploded perspective view of a lock system 100 from the interior side for installation into a door frame 102.

[0104] Lock system 100 comprises an interior door handle furniture 104 having a door handle 105, an exterior door handle furniture 106 having a door handle 107, a central lock assembly 108 having a retractable bolt 109 extending from a first side of central lock assembly 108, and upper and lower multipoint lock assemblies 110A and 110B having retractable bolts 111 A and11 IB respectively, each of multipoint lock assemblies 110A and 110B being operatively connected to central lock assembly 108 via a drive rod 112. The skilled person will appreciate that in alternate embodiments, the lock system omits one or both of upper and lower multipoint lock assemblies 110A and 110B and drive rod 112.

[0105] Central lock assembly 108 advantageously has a slim design with a width that is less than standard locks due to the arrangement of the internal components therein. This is advantageous since it additionally allows lock system 100 to be installed in doors with thinner door frames, such as security doors / screen doors and the like. In particular, and as will be discussed in more detail, the central axis of spindle passage 427 (see also Figure 4) is offset by greater than 25 mm from door engagement surface of door mount tabs 113A and 113B. Preferably, the offset is greater than 26 mm, more preferably greater than 27 mm, even more preferably greater than 28 mm. In this particular embodiment, the offset is about 28.5 mm. The hole openings for furniture bosses and furniture screws are also offset by the same amount.

[0106] Door frame 102 includes edgewise cavities 114, 116A, 116B for receiving central lock assembly 108, and upper and lower multipoint lock assemblies 110A and 110B respectively, and which are affixed thereto by screws.

[0107] Door frame 102 also include first and second lateral openings 120A and 120B which pass from an exterior facing side through to the interior facing side thereof to allow installation of interior door handle furniture 104 and exterior door handle furniture 106 in an operatively connected manner. In particular, door handles 105 and 107 are operatively connected with each other and with central lock assembly 108 via a spindle 122. In this way, when the central lock assembly 108 is in passage mode, either of door handles 105 and 107 may be actuated, such as by a user applying a downward force to rotate handles 105 and 107, to turn spindle 122 and retract bolt 109. Likewise, in this mode, when the user actuates door handles 105 and 107, drive rod 112 is translated from a rest position to an actuated position to retract bolts 111 A and 11 IB within multipoint lock assemblies 110A and 110B respectively. Interior door handle furniture 104 includes button 124 which is operable to unlock the door from the interior side as will be discussed in more detail below.

[0108] Figure 2 is a perspective view illustrating lock system 100 installed on door frame 102 with retractable bolts 109, 111 A, and 11 IB in the extended state, such as when the door withlock system 100 installed thereon is in a closed position. Figure 3 is a perspective view illustrating lock system 100 as per Figure 2 but without door frame 102 and showing the arrangement of central lock assembly 108 and upper and lower multipoint lock assemblies 110A and HOB via drive rod 112.

[0109] Figure 4 and Figure 5 are exploded perspective views of central lock assembly 108 from first and second sides thereof.

[0110] Lock assembly 108 comprises a cartridge housing formed from a cartridge body 400 and cover plate 402 which are affixed together via screws. The cartridge housing contains retractable bolt 109, spindle cam 406, an actuator in the form of slide 408 and driven arm 409, auxiliary bolt 410, a latch locking mechanism in the form of a pivot locking arm 412, and torsion springs 414 and 416. The cartridge housing also contains a motor module 418 having a motor, an electronic door position sensor 420 in communication with motor module 418, a motor driven locking member in the form of a locking slide 422, and a manually actuated lock slide override arm 424.

[0111] Retractable bolt 109 is rotatable about a central mount 404 between an extended position in which an end portion in the form of hook 426 extends outside the cartridge housing to engage with a recess on a strike plate or the like (not shown) and a retracted position in which retractable bolt 109 is substantially housed within the cartridge housing. Retractable bolt 109 is spring biased via torsion spring 414 into the extended position.

[0112] As generally discussed above, retractable bolt 109 can be retracted by a user on rotation of handles 105 and 107 which are engaged with spindle cam 406 via spindle 122. Spindle 122 is engaged in fixed relation with spindle cam 406 via a spindle passage 427 such that actuation of handles 105 and 107 from their rest position also rotates spindle cam 406 via spindle 122. In this embodiment, actuation of handles 105 or 107 causes rotation of spindle cam 406 in a direction such that spindle cam 406 rotates toward the first side of lock assembly 108.

[0113] Spindle cam 406 includes arm 428 with a drive tab 429. Drive tab 429 is seated within upper portion of slot 430 of slide 408 such that on rotation of spindle cam 406 drive tab 429 slides within slot 430 from the upper portion thereof into the lower portion thereof. This in turn causes slide 408 to move longitudinally from its rest position to an actuated position in a direction toward retractable bolt 109.

[0114] Rotation of spindle cam 406, causes surface 406A of spindle cam 406 to contact surface 409A of driven arm 409. This causes driven arm 409 to rotate toward the first side of lock assembly 108. Driven arm 409 is engaged with retractable bolt 109 via a boss 409B which engages within slot 109A of retractable bolt 109. This causes retractable bolt 109 to be moved from the extended position into the retracted position, such that hook portion 426 is substantially withdrawn within the cartridge housing. This is best illustrated in Figure 6 and Figure 7 which provide perspective views of the retractable bolt 109 in the extended position and retracted position respectively. Also shown is torsion spring 414 which is shown in an expanded state in Figure 6 when retractable bolt 109 is extended, and a compressed state in Figure 7 when retractable bolt 109 is retracted. In either case, torsion spring 414 applies a biasing force to move or maintain retractable bolt 109 in the extended position. Consequently, after actuation, and if auxiliary bolt 410 is depressed (e.g. by strike plate) such that retractable bolt 109 is free to move, when a user then releases handle 105 or 107, torsion spring 414 returns retractable bolt 109 to the extended position. Slide 408 is returned to its rest position by handles 105 and / or 107 being sprung to their rest position (e.g., in this embodiment their horizontal orientation as shown in Figure 1). The handle springing occurs due to spring bias housed in door handle furniture 104 and / or 106. Spindle 122 is engaged with handles 105 and 107 such that when handles 105 and 107 are at rest (e.g., in the horizontal orientation as shown in Figure 1, spindle cam 406 is likewise in its rest position, and therefore slide 408 is also in its rest position due to engagement of slot 408 with drive tab 429.

[0115] Figure 6 and Figure 7 also more clearly illustrate the arrangement of components within lock assembly 108. In particular, spindle cam 406 is offset from the central axis of the lock and is located adjacent the second side of central lock assembly 108 opposite the first side. An advantage of offsetting spindle cam 406 to be adjacent to the second side of lock assembly 108, is that it allows for lateral widening and / or thickening of door handle furniture 104 (e.g. in the horizontal x or z directions, with the y direction being the vertical length) to accommodate batteries and electronics in door handle furniture 104 and / or 106, without door handle furniture 104 and / or 106 contacting the doorjamb when the door is opened / closed. To the inventor’s knowledge, offsetting spindle cam 406 so that it is greater than 25mm from a door engagement surface of door mount tabs 113 A and 113B has not been done previously in this type of security door application. In this embodiment, the offset is 28.5 mm, this means that when lock assembly 108 is located within a door, spindle cam 406 is not located centrally within lateral openings 120A and 120B in the door which means that wider door handle furniture 104 and 106 can beused. Due to the location of spindle cam 406 within lock assembly 108, spindle cam 406 is only rotatable in one direction from its rest position where arm 428 rests adjacent the second side to its actuated position. The range of motion of spindle cam 406 is delimited between the rest position and actuated position. This is a departure from lock assemblies that form the central lock assembly of a multi-point lock assembly where the multipoint bolts are extended by handle operation. In such multipoint lock assemblies, the actuator is generally rotatable in a first direction to retract retractable bolts of each of the central lock assembly and the multipoint lock assemblies e.g., which is the same as in lock assembly 108 when operatively connected to multipoint lock assemblies 110A and 110B. However, in other central lock assemblies the actuator is also rotatable from its rest position in a second direction opposite to the first direction to move the retractable bolts of the multipoint lock assemblies to the extended position. This is not possible with the present design since spindle cam 406 can only be rotated in one direction from its rest position.

[0116] In Figure 6, lock assembly 108 is shown in the closed door state with slide 408 and spindle cam 406 in the rest position, retractable bolt 109 in the extended position, and auxiliary bolt 410 in the retracted or depressed position. With auxiliary bolt 410 in the retracted position, pivot locking arm 412 is held above and out of contact with retractable bolt 109. Retractable bolt 109 also includes a detent 600 which abuts against an internal wall of the lock assembly 108.

[0117] In Figure 7, lock assembly 108 is shown in the open door state with slide 408 and spindle cam 406 in the rest position, retractable bolt 109 in the retracted position, and auxiliary bolt 410 in the extended position. With auxiliary bolt 410 in the extended position, pivot locking arm 412 holds retractable bolt 109 in the retracted position via abutment with detent 600 on retractable bolt 109.

[0118] Figure 8 is a perspective view of the rear of lock assembly 108 showing that drive rod 112 engages with a second side of central lock assembly 108 opposite the first side via an engagement pin 800 which is received into bore 802 in slide 408. Thus, actuation of slide 408 between its rest position and actuated position, for example when a user actuates handle 105 or 107, also causes linear translation of drive rod 112 to retract retractable bolts 111A and 11 IB. On release of handle 105 or 107 by a user slide 108 returns to its rest position, and hence drive rod 112 likewise returns to its initial position. As discussed previously, slide 408 is returned to its rest position by handles 105 and / or 107 being sprung to their rest position.

[0119] Auxiliary bolt 410 is located on the first side of lock assembly 108 and is spring biased to the extended position by torsion spring 416. The purpose of auxiliary bolt 410 is to retain retractable bolt 109 in the retracted position when a door in which lock assembly 108 is installed is in the open position. To achieve this, auxiliary bolt 410 cooperates with a latch locking mechanism to hold retractable bolt 109 in the retracted position when auxiliary bolt 410 is in the extended position and to permit movement of retractable bolt 109 when auxiliary bolt 410 is in the retracted position. Auxiliary bolt 410 is shaped such that on closure of a door, auxiliary bolt 410 contacts a surface of a strike plate (not illustrated) which causes auxiliary bolt 410 to be depressed into a retracted position and which provides a physical barrier against the spring bias of torsion spring 416. However, on opening the door lock assembly 108 is moved away from the strike plate, and thus there is no longer a physical barrier which works against the spring bias provided by torsion spring 416, and as such, auxiliary bolt 410 returns to its extended position.

[0120] In this particular embodiment, the bolt locking mechanism is in the form of pivot locking arm 412. When auxiliary bolt 410 is depressed in its retracted position, auxiliary bolt 410 pushes locking arm 412 to a position in which it is disengaged or otherwise separated from retractable bolt 109. In this arrangement, locking arm 412 does not prevent movement of retractable bolt 109 from the retracted position to the extended position. In contrast, when auxiliary bolt 410 is extended, locking arm 412 is configured to engage detent 600 on retractable bolt 109 which holds retractable bolt 109 in the retracted position. To release retractable bolt 109 from being locked in the retracted position by locking arm 412, auxiliary bolt 410 must first be depressed (e.g., which occurs on closure of a door). The effect of this arrangement is that when the door is in an open position retractable bolt 109 is retained in the retracted position and, when the door is in the closed position retractable bolt 109 is able to move from the retracted position to the extended position.

[0121] Cartridge body 400 also includes motor module 418 with a motor therein. The motor and motor module 18 will be discussed in more detail, and in particular, with reference to Figures 9 to 15. Motor module 418 is operatively connected to locking slide 422 to move locking slide 422 between a first position and a second position. In the first position, locking slide 422 does not prevent retractable bolt 109 from being moved from the extended position to the retracted position. However, in the second position, locking slide 422 prevents retractable bolt 109 from being moved from the extended position to the retracted position. That is, locking slide 422 effectively acts to lock retractable bolt 109 in the extended position. In this particularembodiment, locking slide 422 includes a tip 423 which, when in the second position, fits within a notch 500 (best shown in Figure 5) in retractable bolt 109 to physically prevent retractable bolt 109 from being moved from the extended position into the retracted position. As previously discussed, it is preferred that the locking slide has a body formed of plastic to minimize battery power required to actuate locking slide 422. However, since tip 423 engages with other lock body components, and in this embodiment retractable bolt 109, it is desirable that tip 423 be formed of a wear resistant material such as a metal. In some embodiments, tip 423 is separable from the body of lock slide 422. However, in other embodiments, tip 423 is integrally formed or fixedly attached to the body of lock slide 422. Wear resistant materials, such as metals, are typically heavier than plastics. Given this, it is desirable to make tip 423 as small as possible to minimize the weight of locking slide 422 and thus minimize the battery power required to actuate locking slide 422. The skilled person will appreciate that whilst this particular embodiment illustrates direct engagement between locking slide 422 and retractable bolt 109, locking slide 422 may act indirectly on retractable bolt 109 to lock retractable bolt 109 in the extended position.

[0122] Locking slide 422 may be made of any material but preferably comprises a plastic body. Plastic is a light material, and as such, a plastic body requires less battery power to actuate.

[0123] Lock assembly 108 may be configured such that motor in motor module 418 automatically drives locking slide 422 from the first position to the second position on detection that the door is closed and / or that the retractable bolt 109 is in the extended position. However, in other embodiments, the motor in motor module 418 does not automatically drive locking slide 422 on detection that the door is closed and / or the retractable bolt 109 is in the extended position. To achieve this, cartridge body 400 can include one or more position sensors. In this embodiment, cartridge body 400 includes a door sensor 420 which is in electrical communication with motor module 418. Door sensor 420 is operatively coupled with locking arm 412 to detect whether locking arm 412 is engaged or disengaged from retractable bolt 109. Sensing can be via a contact switch or a switch that senses a magnet on locking arm 412 or by other methods generally known to those skilled in the art. As discussed above, locking arm 412 is disengaged from retractable bolt 109 when auxiliary bolt 410 is depressed and retractable bolt 109 is extended which is representative of a ‘door closed’ position, and locking arm 412 is engaged with retractable bolt 109 when auxiliary bolt 410 is extended and retractable bolt 109 is retracted which is representative of a ‘door open’ position. An additional sensor may be presentto determine the position of locking slide 422 and whether this is disengaged from or engaged with retractable bolt 109.

[0124] Door sensor 420 can also be used to inform a user as to whether the door is in the open or closed position. This is so that a user does not think a door is locked when retractable bolt 109 is extended but the door is open.

[0125] To remove the locking of the bolt, a user must provide some form of user credentials, whether in the form of a user entered code, coded keycard, interior button on door handle furniture 104 or the like. On input of an appropriate keycode or detection of a correctly coded key card, motor in motor module 418 moves locking slide 422 from the second position to the first position which permits a user to operate handle 105 or 107 to retract retractable bolt 109 and thereby open the door.

[0126] It is also desirable to include a manual override to remove the locking of the bolt by moving locking slide 422 from the second position to the first position. This is useful in instances where there is an interruption in the power supply to motor module 418. To facilitate this, cover plate 402 comprises an override opening 434 for receiving, for example an override pin driven by an external key cylinder, such as a rotational type or push type key cylinder. Override pin extends through override opening 434 in cover plate 402 and is configured to be engage with lock slide override arm 424. As best illustrated in Figure 6, lock slide override arm 424 comprises a first arm 436 on a first side of pivotal mount 438 and a second arm 440 on a second side of pivotal mount 438. First arm 436 is positioned adjacent override opening 434 and second arm 440 is position adjacent to a nub 442 on locking slide 422. When the manual override is actuated by a user, for example via a key cylinder acting on first arm 436, the lock slide override arm 424 pivots such that second arm 440 pushes against locking slide 422 to move locking slide 422 from its second position to its first position where it is disengaged from retractable bolt 109. A user can then actuate handles 105 or 107 to retract retractable bolt 109.On release of the manual override, e.g. by removal of a key from the key cylinder, the lock slide override arm 424 returns to its rest position under spring bias provided by a spring in motor module 418. Torsion spring 442 keeps lock slide override arm 424 off locking slide 422 so the weight of lock slide override arm 424 is not added to the weight that needs to be driven by motor module 418 which would increase the power requirements of the motor in motor module 418.

[0127] As shown in Figure 6, first arm 436 is shorter than second arm 440, and given this, a small displacement of first arm 436, such as by a key cylinder or the like, results in a relatively larger displacement of second arm 440.

[0128] In some embodiments, motor in motor module 418 is configured to automatically move locking slide 422 from the first position to the second position on detection that the door has been placed into a ‘door closed’ position. Lock system 100 may include an electronically actuated snib or the like on an internal door handle which is pressable by a user to move locking slide from the second position to the first position to allow retractable bolt 109 to then be retracted by actuation of the internal door handle. In this way, the lock system may be operated in a ‘privacy mode’.

[0129] Figure 9 and Figure 10 are a perspective view and a top-down plan view of motor module 418 respectively. Figure 10 illustrates that, in this embodiment, the motor module has a thickness of 10.3 mm which makes it suitable for use in lock assemblies having thin housings / bodies. The thinness of motor module 418 is achieved by the arrangement of components within motor module 418.

[0130] Figure 11 and Figure 12 are front and rear exploded perspective views of motor module 418. Motor module 418 comprises a housing formed from a first casing element 1100 and a second casing element 1102 which are fitted together to contain the elements of motor module 418, such as via snap fit connection, screw connection or the like. Motor module 418 also comprises a motor 1104 in electrical communication with a printed circuit board (PCB) 1106, and a drive mechanism or assembly 1108 which comprises a motor driven shaft in the form of rotary spindle 1110, a motor slide 1112 having an engagement structure for the locking slide in the form of support 1113, and a helical compression spring 1114.

[0131] Motor 1104 has a drive shaft with a drive gear 1116 affixed thereto, and driven shaft 1110 comprises a driven gear 1118. When assembled, Drive gear 1116 is in threaded engagement with a driven gear 1118, such that rotary motion from motor 1104 is transferred from the drive shaft to driven shaft 1110 via communication between drive gear 1116 and driven gear 1118.

[0132] Figures 13, 14, and 15 illustrate motor module 418 in an unlocked state, a locked state, and an override state. Each of these Figures more clearly illustrates the relationship between the components of drive assembly 1108.

[0133] Figure 13 shows that, in the unlocked state, motor slide 1112 is seated in an unlocked position within motor module 418. Motor slide 1112 includes locking slide engagement structure 1113 to which a locking slide e.g., locking slide 422 is fixedly attached. The unlocked position of motor slide 1112 corresponds to the first position of locking slide 422 in which locking slide 422 does not prevent withdrawal of retractable bolt 109. Motor slide 1112 is drivable by motor 1104 to an extended locked position, as shown in Figure 14, which due to fixed connection with locking slide 422 causes tip 423 of locking slide 422 to engage with notch 500 of retractable bolt 108 (when retractable bolt 108 is in the extended position) to lock / prevent retraction of retractable bolt 108.

[0134] Motor slide 1112 is drivable between the unlocked and locked positions via drive assembly 1108. Drive assembly includes drive shaft 1110 comprising driven gear 1118 and drive pins 1120, and helical compression spring 1114 retained within recess 1122 of motor slide 1112. Drive pins 1120 are in threaded engagement with helical compression spring 1114, such when motor 1104 is actuated and rotary motion from motor 1104 is transferred to drive shaft 1110 via drive gear 1116 and driven gear 1118, drive pins 1120 rotate with drive shaft 1110 within the threaded helices of helical compression spring 1114 which causes linear translation of helical compression spring 1114 over drive shaft 1110 and thus linear movement of motor slide 1112 between the unlocked and locked positions.

[0135] Motor module 418 also comprises a lock sensor 1124A to detect the position of motor slide 1112. Lock sensor 1124 may be a magnetic switch, Hall effect sensor or the like, which is configured to detect a magnetic field, such as of a permanent magnet 1126 located in a wing 1128 of motor slide 1112. Movement of motor slide 1112 from the unlocked position (see Figure 13) to the locked position (see Figure 14) causes wing 1128 and thus magnet 1126 to move to a position where it overlays lock sensor 1124A. Lock sensor 1124A detects the presence of magnet 1126 and communicates that the motor slide 1112 is in the locked position to a user via app or similar or used in logic. Also shown is second lock sensor 1124B which is located to detect permanent magnet 1126 when the motor slide 1112 is in the unlocked position, which may likewise be communicated to a used via app or similar or used in logic. For exampleif power has been supplied to motor 1104 to unlock and sensor 1124B does not sense magnet 1126, then the lock will be programmed to repeat the unlocking process again until 1124B does sense magnet 1126. If 1124B does not sense magnet 1126 after X number of tries, then an error message will be sent to the user via app and / or lights and / or sound.

[0136] Figure 15 shows motor module 418 in the override state. In this state, a user has actuated slide override arm 424 which applies a downward force on locking slide 422 to move locking slide 422 from its second position to its first position where it is disengaged from retractable bolt 109. On movement to its first position, locking slide 422 applies a force to motor slide 1112 (denoted by the downward arrow) which causes motor slide 1112 to move against spring bias provided by helical compression spring 1114 from its locked position to its unlocked position. Alternatively slide override arm 424 may act directly on motor slide 1112 to move motor slide 1112 from its locked to unlocked state. Movement of motor slide 1112 during override causes compression of helical compression spring 1112, such that motor slide 1112 is spring biased to its locked position.

[0137] By way of example, if a user were to release actuating slide override arm 424 with retractable bolt 108 in the extended position, helical compression spring 1114 would expand to its uncompressed state which would return motor slide 1112 to its locked position, and in doing so, return slide override arm 424 to its rest position. Locking slide 422 reengages notch 500 of retractable bolt 108 to lock retractable bolt 108 in the extended position. If a user were to actuate retractable bolt 108 to its retracted position and then release actuating slide override arm 424 with retractable bolt 108 in the retracted position, helical compression spring 114 would similarly expand to its uncompressed state returning motor slide 1112 to its locked position and slide override arm 424 to its rest position. Locking slide 422 would then be pushed back to its second position but engaged with a second notch of retractable bolt 108.

[0138] That is, irrespective of whether retractable bolt 108 is in the extended or retracted position, on release of slide override arm 424, locking slide 422 is free to move back to its second position under spring bias of helical compression spring 1114 via movement of tip portion 423 of locking slide 422 into notch 500 (in the case where retractable bolt 108 is extended) or into a second notch (in the case where retractable bolt 108 is retracted).

[0139] This arrangement is illustrated in Figure 29, Figure 30, and Figure 31.

[0140] Figure 29 shows locking slide 422 in its second position engaged with retractable bolt 108 via a bolt abutment surface 2900 (which could also be in the form of a second notch) after release of slide override arm 424 whilst retractable bolt 108 is in the retracted position.

[0141] If slide override arm 424 is released with retractable bolt 108 in the retracted position, then when retractable bolt 108 is moved to its extended position, cam surface 2902 on retractable bolt 108 will push against tip 423 of locking slide 422 causing downward movement of locking slide 422 against helical compression spring 1114 via motor slide 1112 as shown in Figure 30.

[0142] The downward movement of locking slide 422 continues until locking slide 422 rides over cam surface 2902 of retractable bolt 108. When retractable bolt 108 reaches its fully extended position, locking slide 422 is pushed into recess 500 by helical compression spring 1114 via motor slide 1112 to lock retractable bolt 108 in the extended position as shown in Figure 31.

[0143] The operation of the lock will be explained in more detail below with reference to Figures 16 to 22.

[0144] Figure 16 is an internal view of lock assembly 108 showing the arrangement of components when lock assembly 108 is an unlocked operating state with retractable bolt 109 in the extended position, e.g., lock assembly 108 is in passage mode and installed on a door in the closed position. Spindle cam 406 is in the rest position with arm 428 generally oriented vertically adjacent to a wall portion of lock assembly 108 defining the second side of the lock assembly. The rest position of spindle cam 406 corresponds to door handle 105 and 107 being in the neutral position, e.g., unactuated by a user. The arrangement of the spindle cam 406 and arm 428 provides a physical barrier which prevents rotation of spindle cam in a direction toward the second side. Arm 428 comprises drive tab 429 at an end thereof which is located in an upper portion of slot 430 of slide 408 which is also in the rest position.

[0145] In the door closed position, auxiliary bolt 410 is in the depressed position in which pivot locking arm 412 is pushed by auxiliary bolt 410 to a position where it is disengaged from retractable bolt 109. Door position sensor 420 is arranged to detect the position of locking arm 412 and communicate this with motor module 418 or communicate to user via app or similar.

[0146] Door position sensor 420 communicates with motor module 418 via, for example, wiring retained in a recess located within the cartridge housing and extending adjacent a second side of the cartridge housing opposite the first side. The benefit of this arrangement is that the wiring extends out of the housing of lock assembly 108 from a single location as opposed to multiple locations e.g., the wire loom for the sensor 420 extending out a top area of the housing of lock assembly 108 and wire loom for motor module 418 extending out of a bottom area of the housing of lock assembly 108.

[0147] Further by routing the wiring from the sensor into motor module 418 and having a single wire loom extending out of a bottom area of the housing of lock assembly 108, an installer only needs to connect one wiring loom / plug from the lock assembly to external furniture such as an escutcheon during installation. In contrast, if two separate wire looms were used then this would require one loom plug for the sensor and a separate loom plug for the motor module. This causes installation to be more cumbersome and increases the likelihood of damaging wires during installation. Still further, if sensor wiring extended out from the top of lock assembly 108, then it would be close to lateral opening 120A in door frame 102. These cutouts can be sharp and can easily damage wires.

[0148] Another advantage is that by running the wiring along the second side of lock assembly 108, this allows for wire routing without taking up valuable space within the housing of lock assembly 108 or without having to increase the size of the housing (such as depth, length, or thickness) to accommodate that wiring. Increasing the size of the housing of lock body 108 would mean that the lock assembly 108 could not be fitted to doors having small / narrow frames.

[0149] Motor module 418 is in the unlocked state, and thus, locking slide 422 is in the first position where it is disengaged from retractable bolt 109. In particular, motor slide 1112 is seated within motor module 418 in the inactive position with helical compression spring 1114 in the uncompressed state. Pins 1120 are towards the top end of recess 1122. In this position, a user is able to operate handles 105 or 107 to retract retractable bolt 109.

[0150] Figure 17 is an internal view of lock assembly 108 showing the arrangement of components when a user actuates spindle cam 406 via handles 105 or 107 from the unlocked operating state of Figure 16 to retract retractable bolt 109 in a door open position.

[0151] In this position, spindle cam 406 is rotated over its full range of motion from its rest position to its actuated position. The rotational motion of spindle cam 406 causes drive shoulder 406A to act on surface 409A of driven arm 409 to rotationally move driven arm 409 toward the first side of lock assembly 108. Movement of driven arm 409 then causes retraction of bolt 109 via engagement between boss 409B on driven arm with slot 109A in bolt 109.

[0152] The rotational motion of arm 428 also moves slide 408 linearly upward via movement of drive tab 429 from upper portion of slot 430 to lower portion of slot 430. Movement of slide 408 causes corresponding movement of drive rod 112 (if affixed thereto) to actuate remote latches 110A and HOB. Motor module 418 is retained in the unlocked state.

[0153] On opening the door, auxiliary bolt 410 is sprung outward under spring bias provided by torsion spring 416 which causes pivot locking arm 412 to drop into engagement with upper surface of retractable bolt 109. Door position sensor 420 detects the presence of pivot locking arm 412 in the engaged position and communicates this to motor module 418 and / or to a user via app or similar.

[0154] Figure 18 is an internal view of lock assembly 108 showing the arrangement of components after a user has released handles 105 or 107 after actuating lock assembly 108 to open the door as shown in Figure 17 and handles 105 or 107 return to the neutral position.

[0155] After release of handles 105 or 107, retractable bolt 109 is urged toward the extended position under spring bias provided by torsion spring 414. However, retractable bolt 109 is prevented from moving into the extended position due to abutment between pivot locking arm 412 and detent 600 on retractable bolt 109.

[0156] Slide 408 is returned to its rest position from its actuated position by handles 105 and / or 107 being sprung to their rest position. Movement of slide 408 is delimited by its rest and actuated positions.

[0157] On closure of the door, auxiliary bolt 410 comes into contact with a strike plate or the like on an opposing door frame which causes auxiliary bolt 410 to be pressed inward. The inward movement of auxiliary bolt 410 lifts pivot locking arm 412 away from retractable bolt 109. Retractable bolt 109 is then sprung to the extended position under spring bias of torsion spring 414. Pivot locking arm 412 is moved from door position sensor 420 which relays tomotor module 418 or electronics that the lock is in a door close state as generally illustrated in Figure 16. Motor module 418 is retained in the unlocked state.

[0158] Figure 19 is an internal view of lock assembly 108 showing the arrangement of components when lock assembly 108 is in a locked operating state with retractable bolt 109 in the extended position and motor module 418 is in the locked state which causes movement of locking slide 422 to the second position whereby retractable bolt 109 is locked in the extended position, e.g., lock assembly 108 is in a privacy or deadlocked mode and the door is in the closed position.

[0159] As can be seen, the general arrangement of lock components is similar to that illustrated in Figure 16. However, in Figure 19, motor 1108 in motor module 418 has driven motor slide 1112 from the inactive position to the active position, which in turn, moves locking slide from its first position to its second position. In the first position, illustrated in Figure 16, locking slide 422 does not prevent retractable bolt 109 from being moved from the extended position to the retracted position. In the second position, illustrated in Figure 19, locking slide 422 prevents retractable bolt 109 from being moved from the extended position to the retracted position. In particular, locking slide 422 includes tip 423 which is received in a complementary recess in retractable bolt 109 which provides a physical barrier to movement of retractable bolt 109 from the extended position to the retracted position.

[0160] Motor in motor module 418 may be configured to automatically move motor slide 1112 from the inactive position to the active position and thereby moves locking slide 422 from the first position to the second position on detection by door position sensor 420 of a closed door state (e.g., when pivot locking arm 412 is disengaged from retractable bolt 108). In this way, lock assembly 108 automatically locks retractable bolt 108 on door closure.

[0161] Figure 20 is an internal view of lock assembly 108 with motor slide 1112 in the active position and retractable bolt 109 in the extended position, and thus the bolt is locked by locking slide 422. In this state, spindle cam 406 can be partially rotated which permits some movement of retractable bolt 109 toward the retracted state. However, the engagement between locking slide 422 and retractable bolt 109 prevents linear movement of slide 408 which delimits movement of spindle cam 406. In more detail, spindle cam 406 comprises drive tab 429 which is located within slot 430 of slide 408. On rotation of spindle cam 406, drive tab 429 is moveablewithin slot 430 which causes slide 408 to linearly move its rest position to its actuated position. However, when locking slide 422 is engaged with retractable bolt 109, slide 408 is locked in its rest position. Slot 430 has a first portion 430A and a second portion 430B. Movement of drive tab 429 within first portion 430A of slot 430 does not cause linear movement of slide 408. Linear movement of slide 408 is caused by movement of drive tab 429 within second portion 430B of slot 430. Thus, when locked, partial rotation of spindle cam 406 is possible (e.g., by a user actuating a door handle to take up clearances between bolt notch 500 and tip 423 of locking slide 422) which results in drive tab 429 moving within first portion 430A of slot 430. This movement results in partial retraction of retractable bolt 109. However, movement of drive tab 429 through second portion 430B of slot 430 is not possible. This is because locking slide 422 prevents further retraction of retractable bolt 109 and thus locks movement of drive tab 429 from the second portion 430B of slide 430 due to the interaction between drive shoulder 406A on spindle cam 406 and surface 409A of driven arm 409, which in turn, is engaged with retractable bolt 109 via boss 409B on driven arm 409 and slot 109 A in retractable bolt 109. Thus, due to the initial profile of slot 408, slide 408 cannot move while retractable bolt 109 is locked by locking slide 422. This is important as it ensures there is no driving / movement of drive rod 112 when lock assembly 108 is locked, and thus no actuation of the multipoint lock assemblies 110A and HOB when in this state. If movement of slide 408 was possible, then multipoint lock assemblies 110A and 110B could be moved into the non-deadlatched position or partially retracted position whilst locking slide 422 is in the second position (i.e., the locked position).

[0162] Figure 21 is an internal view of lock assembly 108 showing the arrangement of components when the manually actuated lock slide override arm 424 is actuated.

[0163] Starting from the arrangement depicted in Figure 19 where lock assembly 108 is in the locked state, the locked state may be overridden by actuation of lock slide override arm 424. The override may be in the form of a key cylinder which may be, for example, located in the handle or escutcheon on the exterior and / or interior facing surface of the door. In any case, the manual override includes a pin 1400 which projects into the interior of the cartridge housing through opening 434 in cover plate 402. Actuation of the manual override causes lateral movement of the pin to actuate lock slide override arm 424 from the position shown in Figure 19 to the position shown in Figure 21. As can be seen, lock slide override arm 424 is pivoted into contact with locking slide 422 to move locking slide 422 from the second position to thefirst position where it is disengaged from retractable bolt 109 and no longer provides a physical barrier which prevents movement of retractable bolt 109 from the extended position to the retracted position. On movement of locking slide 422 from its second position to its first position, motor slide 1112 is pushed against spring bias of helical compression spring 1114 which compresses helical compression spring 1114 and moves motor slide 1112 from its active position to its inactive position where it is withdrawn within the body of motor module 418.

[0164] Figure 22 follows from Figure 21 and shows that a user is able to actuate spindle cam 406 via handles 105 or 107 to move the door into the open position whilst the override is active. Removal of the override, e.g. by withdrawing a key from a key cylinder results in lock slide override arm 424 being pivoted back to its disengaged position (as illustrated in Figure 17) due to helical compression spring 1114 within motor module 418.

[0165] Figures 23 to 27 illustrate the functioning of central lock assembly 108 as part of a multipoint lock assembly with upper and lower multipoint lock assemblies 110A and 110B.

[0166] Figure 23 illustrates lock body 108 in the same state as Figure 16, that is, lock assembly 108 is in an unlocked door closed state with retractable bolt 109 in the extended position. In the door closed state, retractable bolts 111 A and 11 IB on upper and lower multipoint lock assemblies 110A and 110B are likewise in the extended position.

[0167] Each of the upper and lower multipoint lock assemblies 110A and 110B include an auxiliary bolt 1600A and 1600B respectively which operates in a similar manner to auxiliary bolt 410 in respect of lock assembly 108. That is, the auxiliary bolts 1600A and 1600B cooperate with a latch locking mechanism that is disengaged from retractable bolts 111 A and 11 IB when in the extended state (e.g., corresponding to a door closed position) and engaged with retractable bolts 111A and 11 IB when in the retracted state (e.g., corresponding to a door open position) to hold retractable bolts 111 A and 11 IB in the retracted state until the door is closed and auxiliary bolts 1600A and 1600B are depressed.

[0168] In Figure 23, lock assembly 108 is in an unlocked door closed state, and as such, auxiliary bolts 1600A and 1600B are depressed.

[0169] Figure 24 illustrates lock body 108 in the same state as Figure 17. That is, a user has actuated handle 105 or 107 to retract retractable bolt 109. As generally described in relation toFigure 17, actuation of handle 105 or 107 causes spindle cam 108 to be rotated over its full range of motion from its rest position to its actuated position. The rotational motion of arm 428 of spindle cam 108 moves slide 408 linearly upward via movement of drive tab 429 from upper portion of slot 430 to lower portion of slot 430.

[0170] Slide 408 includes coupling structure in the form of bore 802 (shown in dashed lines denoting that coupling structure 802 is hidden from view) for fixed coupling with drive rod 112. In particular, drive rod 112 has an engagement pin 800 which fits into bore 802 such that drive rod 112 and slide 408 are fixed relative to each other. Given this fixed relationship, translation of slide 408 between the rest and actuated positions likewise causes translation of drive rod 112 between a rest and an actuated position thereof. Thus, actuation of slide 408 between its rest position and actuated position, for example on user actuation of handle 105 or 107, causes linear translation of drive rod 112 to retract retractable bolts 111 A and 11 IB as illustrated in Figure 24.

[0171] In Figure 24, lock assembly 108 is in an unlocked door open state, and as such, auxiliary bolts 1600A and 1600B are moved to the extend position under spring bias.

[0172] Figure 25 illustrates lock body 108 in the same state as Figure 18. That is, the user has actuated handle 105 or 107 to retract retractable bolt 109 and open the door, and the user has subsequently released handle 105 or 107 to allow handles 105 and 107 to return to their neutral position. In Figure 25, slide 408 has returned to its rest position and as such, drive rod 112 has been moved to its rest position. However, movement of drive rod 112 from its actuated position to its rest position does not affect retractable bolts 111A and 11 IB. Retractable bolts 111A and 11 IB remain locked in the retracted state by the latch locking mechanism.

[0173] Figure 26 illustrates lock body 108 in the same state as Figure 19. That is, locking slide 422 is in the second position engaged with retractable bolt 109 to lock retractable bolt 109 in place. As a result of this arrangement, slide 408 cannot be moved from its rest position to the actuated position, and consequently, retractable bolts 111 A and 11 IB are likewise locked in their extended position.

[0174] Figure 27 illustrates lock body 108 in the same state as Figure 20. That is, locking slide 422 is in the second position engaged with retractable bolt 109 to lock retractable bolt 109 in place. In Figure 27, a user has actuated a door handle which has caused partial rotation ofspindle cam 108 and thus movement of drive tab 429 within the first portion 430A of slot 430 of slide 408. This movement of spindle cam 108 also causes partial retraction of retractable bolt 109. However, as discussed previously, locking slide 422 prevents full retraction of retractable bolt 109 and thus also locks spindle cam 108 from further rotational movement. Given this, drive tab 429 cannot move into second portion 430B of slide 430, and consequently slide 430 is locked from linear movement from its rest position. Since slide 430 cannot be moved, actuation of spindle cam 108 does not cause movement of drive rod 112, and thus multipoint lock assemblies 110A and HOB cannot be actuated.

[0175] Figure 28 illustrates a partial view of a door frame 102 with a lock assembly 108 installed therein. In particular, Figure 28 shows that due to the axis of spindle cam 406 being offset by greater than 25 mm from door engagement surface of door mount tabs 113 A and 113B (not visible in Figure 28), spindle cam 406 is not located centrally within lateral openings 120A and 120B of door frame 102. If spindle cam 406 were located centrally within lateral openings 120A and 120B (which would be the case if a typical offset of 25 mm was used), then door handle furniture 106 would need to be positioned nearer a leading edge of door frame 102, which in turn means that door handle furniture 106 would be installed too close to the leading edge of door frame 102 and may contact the doorjamb. This is particularly problematic for electronic locks since these are generally wider than door furniture / escutcheons for nonelectronic locks since they are additionally required to house components such as motors, batteries, printed circuit boards and the like. Screw hole locations in the lock assembly are also offset.

[0176] The skilled person will appreciate that the lock assembly may further comprises a user actuatable release mechanism which, when actuated by a user, generates an electronic control signal to operate the motor to move the locking slide from the second position to the first position. By way of example, the user actuatable release mechanism comprises a push button on an escutcheon or a handle configured for installation on an interior facing side of a door and / or the user actuatable release mechanism may be via smart phone application or the like (see for example push button 124 on interior door handle furniture 104 in Figure 1).

[0177] In such embodiments, the lock assembly is operable in: (i) a passage mode, wherein the locking slide is in the first position and the spindle cam is rotatable by a user to actuate the bolt from the extended position to the retracted position; (ii) a privacy mode, wherein the lockingslide is in the second position and is movable into the first position on actuation of the actuatable release mechanism; and optionally (iii) a deadlocked mode, wherein the locking slide is in the second position and is only movable into the first position on actuation of the motor or by use of a user override key.

[0178] Figure 32 is an exploded perspective view of key cylinder 3100 according to one embodiment of the invention. In this embodiment, key cylinder 3100 is a rotational type key cylinder. However, the skilled person will appreciate that other types of key cylinders can be used, such as push-type key cylinders. Key cylinder 3100 includes a casing 3102 with internal passage 3104; a key barrel 3106 configured to be rotated within internal passage 3104 and having an exterior facing end 3108 with keyhole holding key 3110, an interior facing end 3112, a drive channel 3114 formed in barrel 3106, a pin-tumbler assembly 3116 having cap 3118 for retaining pins in pin-tumbler assembly 3116; a linearly drivable shaft 3120 including a driven pin 3122 which is seated in drive channel 3114 to drive linearly drivable shaft 3120 between a retracted position and an extended position on rotation of key 3110; linearly drivable shaft 3120 also comprising an override pin assembly 3124 having a shaft 3126, a sheath 3128 which is located in slidable relationship with shaft 3126 via spring 3130 and locking bar 3132.

[0179] When assembled, barrel 3106 is inserted into passage 3104 of casing 3102 in rotational relationship therewith. Barrel 3106 is held in rotational engagement with casing 3102 via circlip 3134.

[0180] Rotation of key 3110 causes rotation of barrel 3106 within passage 3104 of casing 3102. Driven pin 3122 of linear linearly drivable shaft 3120 is seated within passage 3104, and as such, rotation of barrel 3106 moves driven pin 3122 between the first and second ends of passage 3114 which translates to linear movement of linearly drivable shaft 3120 between a neutral retracted position and an engaged extended position. This linear movement of linearly drivable shaft 3120 moves override pin 3124 between a disengaged position corresponding to the retracted position of linearly drivable shaft 3120 (where override pin 3124 does not actuate an override mechanism of the lock) and an engaged position corresponding to the extended position of linearly drivable shaft 3120 (where override pin 3124 actuates an override mechanism of the lock). In particular, in the override position, pin assembly 3124 is pressed into engagement with an override mechanism in a lock assembly, such as lock assembly 112 (in which case, override pin 3124 is equivalent to override pin 1400 of Figures 16 to 22).

[0181] Whilst the override pin may be in the form of a simple shaft, the inventors have devised override pin 3124 with adaptable pin length for use with doors of different thicknesses. This is achieved, in this embodiment, by having a shaft 3126 and sheath 3128 arrangement with sheath 3128 being slidably mounted over shaft 3126 via spring 3130 and locking bar 3132. In particular, spring 3130 is fitted within a recess of sheath 3128 and is held within the recess between a top surface of shaft 3126 and an internal ceiling of sheath 3128. Locking bar 3132 is passed through windows 3136 of sheath 3128 and passage 3136 of shaft 3126 to mount sheath 3128 to shaft 3126. Slidable movement of sheath 3128 over shaft 3126 is delimited by the height of windows 3136, such that sheath 3128 and shaft 3126 have a close together arrangement corresponding to a short pin length and a spaced apart arrangement corresponding to a long pin length. Spring 3130 biases sheath 3128 from shaft 3126 into the spaced apart arrangement such that override pin 3124 has a long pin length.

[0182] Figure 33 and Figure 34 illustrate a key cylinder 3100 in the neutral retracted position with the override pin assembly having a long pin length (see Figure 33) such as when installed in a thick door and a short pin length (see Figure 34) such as when installed in a thin door. Figure 33 illustrates that sheath 3128 and shaft 3126 are biased apart by spring 3130 into the expanded state. Pin 3132 is located at the bottom of window 3136 which delimits the expanded state. Figure 34 illustrates that sheath 3128 and shaft 3126 are pushed together against the bias of spring 3130 into the contracted state. Pin 3132 is located at the top of window 3136 which delimits the contracted state.

[0183] Figure 35 and Figure 36 illustrate an escutcheon 3400, such as internal door furniture 104 or external door furniture 108 from Figures 1 and 2 with a key cylinder to actuate the override mechanism installed therein (which may for example be key cylinder 3100). Escutcheon 3400 includes a front plate 3402, and back plate 3404, a handle 3406 mounted to front plate 3402, an opening 3108 in back plate 3402 with an override pin 3410 of a key cylinder extending therethrough. Also shown is spindle 3412 which is operatively connected to handle 3406.

[0184] Figure 35 illustrates escutcheon 3400 with key cylinder in the neutral position and with a key inserted therein. Handle 3406 is rendered inoperable for retracting a bolt due to engagement of a locking slide with an actuation mechanism associated with the bolt and / or with the bolt itself. Override pin 3410 is in a position where it is disengaged from an overridemechanism of an associated lock body or to otherwise causes the override mechanism to be disengaged from an internal locking mechanism within the associated lock body.

[0185] Figure 36 illustrates escutcheon 3400 with key cylinder in the override position and with key inserted therein and rotated (denoted by the arrow in Figure 36) to linearly move override pin 3410 into an override position to engage an override mechanism of an associated lock body or to otherwise cause the override mechanism to be engaged with an internal locking mechanism within the associated lock body to permit handle 2106 to retract a bolt on rotation thereof.

[0186] The above embodiment describes an override pin 3124 that is adapted to suit a rotational style key cylinder. However, the skilled person will appreciate that override pin 3124 could be adapted for use with, for example, a push style key cylinder.

[0187] It will be understood that the invention disclosed and defined in this specification extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations constitute various alternative aspects of the invention.

Claims

CLAIMS1. A lock assembly comprising: a cartridge housing containing: a bolt having a retracted position and an extended position in which the bolt extends out of the cartridge housing; a motor module comprising a motor; and a locking member operatively connected to the motor, the motor operable to drive the locking member between a first position and a second position, wherein: in the first position the locking member does not prevent the bolt from being moved from the extended position to the retracted position, and in the second position the locking member prevents the bolt from being moved from the extended position to the retracted position.

2. The lock assembly of claim 1, wherein: the cartridge housing further contains a manually actuatable override having a rest position and an override position, the manually actuatable override engaged with, or engageable with, the locking member on movement from its rest position to its override position to move the locking member from its second position to its first position; and the manually actuatable override is configured to move from its rest position to its override position on application of a force thereto, and the bolt is actuatable from its extended position to its retracted position while the manually actuatable override is held by application of the force in its override position.

3. The lock assembly of claim 2, wherein: the manually actuatable override is configured to move the locking member from the second position to the first position against a spring bias, the force being sufficient to overcome the spring bias, and wherein the spring bias is provided by a spring housed within the motor module; and on release of the force, the spring bias is configured to move the locking member from the first position to the second position.

4. The lock assembly of claim 2 or 3, wherein the manually actuatable override comprises:an input portion mechanically displaceable by a user over a first length, and an output portion operatively engaged with the input portion and the locking member, the output portion being displaceable over a second length when the input portion is displaced the first length to move the locking member from the second position to the first position; and wherein the second length is greater than the first length.

5. The lock assembly of claim 1, wherein the motor module further contains a motor drive mechanism, the motor drive mechanism operatively connected to the motor, the motor drive mechanism configured to convert rotational motion of the motor into linear motion to drive the locking member between the first position and the second position.

6. The lock assembly of claim 5, wherein the motor drive mechanism comprises: a motor driven shaft; and a support engaged with the motor driven shaft such that rotation of the driven shaft causes linear movement of the support in an axial direction along the driven shaft between an unlocked position corresponding to the first position of the locking member and a locked position corresponding to the second position of the locking member.

7. The lock assembly of claim 6, wherein the driven shaft and support are operatively connected via a spring, and wherein: the cartridge housing further contains a manually actuatable override having a rest position and an override position, and wherein on moving the manually actuatable override from the rest position to the override position, the support is moved relative to the driven shaft to the unlocked position against a spring bias of the spring; and / or the spring is a helical compression spring, the spring comprising a helical body in threaded engagement with a at least one projection on the driven shaft such that rotation of the driven shaft causes linear movement of the spring along a longitudinal axis of the driven shaft.

8. The lock assembly of any one of the preceding claims, wherein the cartridge housing further contains one or more sensors configured to detect if the locking member is in the first position and / or in the second position.

9. The lock assembly of claims 6 or 7, wherein the cartridge housing further contains one or more sensors configured to detect if the support is in the first position and / or in the second position.

10. The lock assembly of claim 8 or 9, wherein the one or more sensors are located in the motor module.

11. The lock assembly of any one of the preceding claims, wherein the cartridge housing further contains a spindle cam having a spindle passage for receiving a spindle therethrough, the spindle cam being rotatable by a user from a rest position to an actuated position to actuate the bolt from the extended position to the retracted position; wherein: when the locking member is in the first position, the spindle cam is rotatable by a user from a rest position to an actuated position to actuate the bolt from the extended position to the retracted position; and when the locking member is in the second position, the spindle cam is locked from rotation into the actuated position.

12. The lock assembly of any one of the preceding claims, wherein the lock assembly further comprises a user actuatable release mechanism which, when actuated by a user, generates an electronic control signal to operate the motor to move the locking member from the second position to the first position.

13. The lock assembly of claim 12, wherein the lock assembly is operable in: a passage mode, wherein the locking member is in the first position and the spindle cam is rotatable by a user to actuate the bolt from the extended position to the retracted position; and a privacy mode, wherein the locking member is in the second position and is movable into the first position on actuation of the user actuatable release mechanism.

14. The lock assembly of any one of the preceding claims, wherein the lock assembly is operable in a deadlocked mode, wherein the locking member is in the second position and cannot be actuated by operation of the user actuatable release mechanism.

15. The lock assembly of any one of claims 11 to 14, wherein the cartridge housing further contains a main slide, the spindle cam configured to move the main slide from a first main slide position to a second main slide position on rotation of the spindle cam from its rest position to its actuated position, and when the locking member is in the second position, the main slide cannot be moved into the second main slide position.

16. The lock assembly of any one of the preceding claims, wherein when the locking member is in the second position and the bolt is in the extended position, the locking member engages with a first shoulder on the bolt to prevent the bolt from being moved from the extended position to the retracted position.

17. The lock assembly of claim 16, wherein when the bolt is in the retracted position, the locking member can be in the first position or the second position or an intermediate position between the first position and the second position.

18. The lock assembly of claim 17, wherein: the bolt comprises a cam surface configured to push the locking member towards its first position on movement of the bolt from its retracted position towards its extended position; and the cam surface pushes the locking member against a spring bias, and wherein when the bolt is moved into the extended position, the locking member is configured to be moved to the second position and into, or into proximity of, the first shoulder by the spring bias.

19. The lock assembly of any one of the preceding claims, wherein the lock assembly further comprises a user actuatable key cylinder, the key cylinder having an engagement structure engaged with, or engageable with, a or the manually actuatable override, wherein on actuation by a user, the key cylinder is configured to apply a or the force to the manually actuatable override to move the manually actuatable override from a or the rest position to an or the override position.

20. The lock assembly of claim 19, wherein the cartridge housing comprises an opening through which the engagement structure engages with, or is engageable with, the manually actuatable override, and wherein the engagement structure projects through the opening and into the cartridge housing to engage with, or be engageable with, the manually actuatable override.

21. The lock assembly of claim 19 or 20, wherein the key cylinder comprises: a housing having a passage defining a longitudinal axis; a barrel comprising: an exterior facing end having a key slot for insertion of a key in a key insertion direction generally along or aligned with the longitudinal axis; and an interior facing end having an engagement structure for engagement with the actuator of the manual override mechanism;wherein the barrel is mounted within the housing, and on location of a correctly coded key within the key slot and, on application of a force thereto, is operable from a rest position to an engaged position to longitudinally move the engagement structure from its rest position to its override position.

22. The lock assembly of any one of claims 19 to 21, wherein: the engagement structure is an engagement pin, and the engagement pin is configured to project through an opening in the cartridge housing for engagement with the manually actuatable override, the engagement pin has an adaptable length along a pin axis; and the engagement pin comprises a first pin portion and a second pin portion, the second pin portion being mounted to the first pin portion, the first pin portion and the second pin portion being movable relative to one another in a direction along the pin axis between a contracted state and an elongated state; and wherein the first pin portion and the second pin portion are spring biased to the elongated state, and / or the first pin portion is a shaft and the second pin portion is a sheath, the sheath being slidably and coaxially mounted to the shaft.

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