Electric strike including a biasing mechanism for a keeper support bracket

Abstract

An actuator controlled electric strike for operating in conjunction with a latch of a lockset. The strike comprises a keeper support bracket movable between first and second positions. When the bracket is in the first position a keeper is held in either a locked or unlocked position, and when the bracket is in the second position the keeper is movable to the other position. An actuating mechanism is operatively connected to the bracket and is configured to allow the bracket to move between the first and second positions. First and second biasing mechanisms apply a net force to the bracket. The first biasing mechanism applies a first force to the bracket in the first direction, and the second biasing mechanism applies a second force to the bracket in the second direction. When the bracket is in the first position, the net force of the biasing member is approximately zero.

Claims

1. An actuator-controlled electric strike for operating in conjunction with a latch of a lockset, wherein the latch has an engaged position so as to secure a door in a closed state and a released position, the strike comprising: a) a housing defining an entry chamber therein; b) a keeper disposed in said entry chamber, wherein said keeper is movable between a locked position and an unlocked position; c) a keeper support bracket movable between a first position and a second position, wherein when said keeper support bracket is in said first position, said keeper is in one of said locked position or said unlocked position, and wherein when said keeper support bracket is in said second position said keeper is in the other of said locked position or said unlocked position; d) an actuating mechanism operatively connected to said keeper support bracket, wherein said actuating mechanism is actionable in a first direction to move said keeper support bracket toward said first position, and wherein said actuating mechanism is configured to allow said keeper support bracket to move in a second direction toward said second position, wherein said second direction is different than said first direction; and e) a biasing member applying a net force to said keeper support bracket, said biasing member comprising a first biasing mechanism and a second biasing mechanism, wherein said first biasing mechanism has at least one biasing characteristic value different from that of the said second biasing mechanism, wherein said first biasing mechanism applies a first force to said keeper support bracket in said first direction, wherein said second biasing mechanism applies a second force to said keeper support bracket in said second direction, and wherein when said keeper support bracket is in said first position, said net force of said biasing member is approximately zero.

2. The strike in accordance with claim 1 wherein said second direction is opposite of said first direction.

3. The strike in accordance with claim 1 wherein said first biasing mechanism comprises a first spring having a first spring constant, wherein said second biasing mechanism comprises a second spring having a second spring constant different from said first spring constant, and wherein said at least one biasing characteristic value comprises said first spring constant and said second spring constant.

4. The strike in accordance with claim 1 wherein said keeper support bracket includes an actuator extension that is operatively coupled to said actuating mechanism, and wherein said keeper support bracket is selectively moveable by said actuating mechanism between said first position and said second position.

5. The strike in accordance with claim 1 wherein said actuating mechanism is a stepper motor.

6. The strike in accordance with claim 1 further comprising a keeper release operatively coupled between said keeper support bracket and said keeper.

7. The strike in accordance with claim 1 further comprising a carrier operatively connected between said actuating mechanism and said keeper support bracket.

8. The strike in accordance with claim 7 wherein said carrier is formed of a polyether ether ketone polymer.

9. The strike in accordance with claim 7 wherein said actuating mechanism is a stepper motor, wherein said stepper motor includes a lead screw having a screw thread, said motor carrier has a carrier thread mateable with said screw thread, wherein when said stepper motor is actionable in either said first direction or said second direction, said motor carrier acts upon said keeper support bracket to move said keeper support bracket between said first position and said second position.

10. A method of improving the performance of an electric strike, wherein said electric strike includes a keeper movable between a locked position and an unlocked position, and a support bracket movable by an actuating mechanism between a first position and a second position, wherein when said support bracket is in said first position said keeper is in one of said locked position or said unlocked position, and wherein when said support bracket is in said second position said keeper is in the other of said locked position or said unlocked position, said method comprises the steps of: a) providing a first biasing mechanism operatively coupled to said support bracket to apply a first force in a first direction to move said support bracket toward said first position, wherein said first biasing mechanism includes a first biasing characteristic value; b) providing a second biasing mechanism operatively coupled to said support bracket to apply a second force in a second direction opposite said first direction to move said support bracket toward said second position, wherein said second biasing mechanism includes a second biasing characteristic value that is different than said first biasing characteristic value; c) selecting said first and second biasing characteristic values so that a net force exerted on said support bracket by said first and second biasing mechanisms is approximately zero when said support bracket is in said first position, whereby said performance of said electric strike is improved by increasing an acceleration of said support bracket upon an initial movement of said support bracket toward one of said first position or said second position by said actuating mechanism.

11. The method in accordance with claim 10 wherein said first biasing characteristic value comprises a first spring constant, and wherein said second biasing characteristic value comprises a second spring constant different from said first spring constant.

12. The method in accordance with claim 11 comprising the further step of selecting said first and second spring constants so that said net force exerted on said support bracket by said first and second biasing mechanisms is positive in said first direction applied in said second direction when said support bracket is in said second position.

13. An actuator module for an electric strike for operating in conjunction with a latch of a lockset, wherein said latch has an engaged position so as to secure a door in a closed state and a released position, wherein said electric strike comprises a housing defining an entry chamber and a keeper disposed in said entry chamber movable between a locked position and an unlocked position, wherein said actuator module comprises: a) a keeper support bracket movable between a blocking position and an unblocking position, wherein when said keeper support bracket is in said blocking position, said keeper is held in said locked position, and wherein when said keeper support bracket is in said unblocking position said keeper is able to be moved to said unlocked position; b) an actuating mechanism operatively connected to said keeper support bracket and actionable in a first direction to move said keeper support bracket toward said blocking position, and actionable in a second direction to move said keeper support bracket toward said unblocking position, wherein said second direction is different than said first direction; and c) a biasing member applying a net force to said keeper support bracket, said biasing member comprising a first biasing mechanism and a second biasing mechanism, wherein a first biasing characteristic value of said first biasing mechanism is different than a second biasing characteristic value of said second spring, wherein said first biasing mechanism applies a first force to said keeper support bracket in said first direction, wherein said second biasing mechanism applies a second force to said keeper support bracket in said second direction, and wherein when said keeper support bracket is in said blocking position, said net force of said biasing member is approximately zero.

14. The strike in accordance with claim 13 wherein said second direction is opposite of said first direction.

15. The strike in accordance with claim 13 wherein said first biasing mechanism comprises a first spring having a first spring constant, wherein said second biasing mechanism comprises a second spring having a second spring constant different from said first spring constant, and wherein said at least one biasing characteristic value comprises said first spring constant and said second spring constant.

16. The actuator module in accordance with claim 13 wherein said keeper support bracket includes an actuator extension that is operatively coupled to said actuating mechanism, and wherein said keeper support bracket is selectively moveable by said actuating mechanism between said blocking position and said unblocking position.

17. The actuator module in accordance with claim 13 wherein said actuating mechanism is a stepper motor.

18. The actuator module in accordance with claim 13 further comprising a carrier operatively connected between said actuating mechanism and said keeper support bracket.

19. The actuator module in accordance with claim 18 wherein said carrier is formed of a polyether ether ketone polymer.

20. The actuator module in accordance with claim 18 wherein said actuating mechanism is a stepper motor, wherein said stepper motor includes a lead screw having a screw thread, said carrier has a carrier thread mateable with said screw thread, wherein when said stepper motor is actionable in either said first direction or said second direction, said carrier acts upon said keeper support bracket to move said keeper support bracket between said blocking position and said unblocking position.

21. A method of improving the performance of an actuator module of an electric strike, wherein said electric strike includes a keeper movable between a locked position and an unlocked position, wherein said actuator module includes a support bracket movable by an actuating mechanism between a blocking position and an unblocking position, wherein when said support bracket is in said blocking position said keeper is in said locked position, and wherein when said support bracket is in said unblocking position said keeper is in said unlocked position, said method comprises the steps of: a) providing a first biasing mechanism operatively coupled to said support bracket to apply a first force in a first direction to move said support bracket toward said blocking position, wherein said first biasing mechanism includes a first biasing characteristic value; b) providing a second biasing mechanism operatively coupled to said support bracket to apply a second force in a second direction opposite said first direction to move said support bracket toward said unblocking position, wherein said second biasing mechanism includes a second biasing characteristic value that is different than said first biasing characteristic value; c) selecting said first and second biasing characteristic values so that a net force exerted on said support bracket by said first and second biasing mechanisms is approximately zero when said support bracket is in said blocking position, whereby said performance of said actuator module is improved by increasing an acceleration of said support bracket upon an initial movement of said support bracket toward said unblocking position by said actuating mechanism.

22. The method in accordance with claim 21 wherein said first biasing characteristic value comprises a first spring constant, and wherein said second biasing characteristic value comprises a second spring constant different from said first spring constant.

23. The method in accordance with claim 22 comprising the further step of selecting said first and second spring constants so that said net force exerted on said support bracket by said first and second biasing mechanisms is positive in said first direction applied in said unblocking direction when said support bracket is in said unblocking position.

24. An actuator module for an electric strike for operating in conjunction with a latch of a lockset, wherein said latch has an engaged position so as to secure a door in a closed state and a released position, wherein said electric strike comprises a housing defining an entry chamber and a keeper disposed in said entry chamber movable between a locked position and an unlocked position, wherein said actuator module comprises: a) a keeper support bracket movable between a first position a second position, wherein when said keeper support bracket is in said first position, said keeper is in one of said locked position or said unlocked position, and wherein when said keeper support bracket is in said second position said keeper is in the other of said locked position or said unlocked position; b) an actuating mechanism operatively connected to said keeper support bracket, wherein said actuating mechanism is actionable in a first direction to move said keeper support bracket toward said first position, and wherein said actuating mechanism is configured to allow said keeper support bracket to move in a second direction toward said second position, wherein said second direction is different than said first direction; and c) a biasing member applying a net force to said keeper support bracket, said biasing member comprising a first biasing mechanism and a second biasing mechanism, wherein said first biasing mechanism has at least one biasing characteristic value different from that of said second biasing mechanism, wherein said first biasing mechanism applies a first force to said keeper support bracket in said first direction, wherein said second biasing mechanism applies a second force to said keeper support bracket in said second direction, and wherein when said keeper support bracket is in said first position, said net force of said biasing member is approximately zero.

25. The strike in accordance with claim 24 wherein said second direction is opposite of said first direction.

26. The strike in accordance with claim 24 wherein said first biasing mechanism comprises a first spring having a first spring constant, wherein said second biasing mechanism comprises a second spring having a second spring constant different from said first spring constant, and wherein said at least one biasing characteristic value comprises said first spring constant and said second spring constant.

27. The actuator module in accordance with claim 24 wherein said keeper support bracket includes an actuator extension that is operatively coupled to said actuating mechanism, and wherein said keeper support bracket is selectively moveable by said actuating mechanism between said first position and said second position.

28. The actuator module in accordance with claim 24 wherein said actuating mechanism is a stepper motor.

29. The actuator module in accordance with claim 24 further comprising a carrier operatively connected between said actuating mechanism and said keeper support bracket.

30. The actuator module in accordance with claim 29 wherein said carrier is formed of a polyether ether ketone polymer.

31. The actuator module in accordance with claim 30 wherein said actuating mechanism is a stepper motor, wherein said stepper motor includes a lead screw having a screw thread, said carrier has a carrier thread mateable with said screw thread, wherein when said stepper motor is actionable in either said first direction or said second direction, said carrier acts upon said keeper support bracket to move said keeper support bracket between said first position and said second position.

32. A method of improving the performance of an actuator module of an electric strike, wherein said electric strike includes a keeper movable between a locked position and an unlocked position, wherein said actuator module includes a support bracket movable by an actuating mechanism between a first position and a second position, wherein when said support bracket is in said first position said keeper is in one of said locked position or said unlocked position, and wherein when said support bracket is in said second position said keeper is in the other of said locked position or said unlocked position, said method comprises the steps of: a) providing a first biasing mechanism operatively coupled to said support bracket to apply a first force in a first direction to move said support bracket toward said first position, wherein said first biasing mechanism includes a first biasing characteristic value; b) providing a second biasing mechanism operatively coupled to said support bracket to apply a second force in a second direction opposite said first direction to move said support bracket toward said second position, wherein said second biasing mechanism includes a second biasing characteristic value that is different than said first biasing characteristic value; c) selecting said first and second biasing characteristic values so that a net force exerted on said support bracket by said first and second biasing mechanisms is approximately zero when said support bracket is in said first position, whereby said performance of said actuator module is improved by increasing an acceleration of said support bracket upon an initial movement of said support bracket toward one of said first position or said second position by said actuating mechanism.

33. The method in accordance with claim 32 wherein said first biasing characteristic value comprises a first spring constant, and wherein said second biasing characteristic value comprises a second spring constant different from said first spring constant.

34. The method in accordance with claim 33 comprising the further step of selecting said first and second spring constants so that said net force exerted on said support bracket by said first and second biasing mechanisms is positive in said first direction applied in said second direction when said support bracket is in said second position.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:

(2) FIG. 1 is a perspective view of an actuator-controlled electric strike in accordance with the present invention;

(3) FIG. 2 is an exploded view of the actuator-controlled electric strike shown in FIG. 1;

(4) FIG. 3 is a side view of the actuator-controlled electric strike shown in FIG. 1 with the housing shown in phantom view including a strike plate, and the keeper in the locked position;

(5) FIG. 4 is a side perspective view of the actuator-controlled electric strike taken along line 4-4 in FIG. 1;

(6) FIG. 5 is a top perspective view of an embodiment of an actuator module used with the actuator-controlled electric strike shown in FIG. 1 wherein the module housing is shown in phantom;

(7) FIG. 6 is a side view of the actuator-controlled electric strike shown in FIG. 1 with the housing shown in phantom view including the strike plate, and the keeper in the unlocked position;

(8) FIG. 7 is a side perspective view of the actuator-controlled electric strike shown in FIG. 6 along the same line as 4-4 in FIG. 1;

(9) FIG. 8 is a partial exploded bottom perspective view of an embodiment of an actuator module used with the actuator-controlled electric strike shown in FIG. 1;

(10) FIG. 9 is a schematic view of actuator circuit for use with an actuator-controlled electric strike in accordance with the present invention;

(11) FIG. 10 is a representative current diagram using the circuit shown in FIG. 9;

(12) FIG. 11 is a cross sectional perspective view of an actuator-controlled electric strike having an adjustable strike shim in accordance with the present invention with the adjustable strike flush with the keeper;

(13) FIG. 12 is a cross sectional perspective view of an actuator-controlled electric strike similar to FIG. 11 having the adjustable strike shim extending inwardly from with the keeper;

(14) FIG. 13 is a perspective view of an actuator-controlled electric strike including latch bolt monitors in accordance with the present invention;

(15) FIG. 14 is a perspective view of an actuator-controlled electric strike including a trim plate in accordance with the present invention;

(16) FIG. 15 shows various strike plates that may be used an actuator-controlled electric strike in accordance with the present invention;

(17) FIG. 16 is an exploded view of an actuator-controlled electric strike including a deadbolt bracket in accordance with the present invention;

(18) FIG. 17 is a perspective view of the actuator-controlled electric strike including a deadbolt bracket shown in FIG. 16;

(19) FIG. 18 is a perspective view of a prior art electric strike;

(20) FIG. 19 is a perspective view of a prior art mortise lock set;

(21) FIG. 20A is a perspective view of the actuator controlled electric strike in accordance with the invention and installed in a standard door frame;

(22) FIG. 20B is a perspective view of the actuator controlled electric strike in accordance with the invention and installed in a door frame that is wider than the door frame shown in FIG. 20A;

(23) FIG. 21 is a perspective, exploded view of a lip extension and electric strike as shown in FIG. 20B, in accordance with the invention;

(24) FIG. 22 is a cross-section of a stepper motor driven actuator taken along line 22-22 in FIG. 23B;

(25) FIG. 23A is a perspective view of the actuator shown in FIG. 23B with a support bracket shown in the unlocked position;

(26) FIG. 23B is a perspective view of the actuator with the support bracket shown in the locked position;

(27) FIG. 24 is a cross-sectional view of the actuator taken along line 24-24 in FIG. 23B; and

(28) FIG. 25 is a chart showing the forces exerted on the support bracket between the locked position and unlocked position.

(29) Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate currently preferred embodiments of the present invention, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

(30) Referring now to FIGS. 1 and 2, an embodiment of an actuator-controlled electric strike having an interchangeable, unitized actuator module 26, in accordance with the present invention, is generally indicated by reference numeral 20. Strike 20 generally comprises a housing 22 and a keeper 24 rotatably mounted thereto. Unitized actuator module 26 (comprising a body 61 and an actuator 69 and a keeper release 62, wherein actuator 69 is contained within body 61 and at least a portion of keeper release 62 is contained within body 61see FIG. 5), when inserted into housing 22 as a unit, is configured to cooperate with keeper 24 so as to control locking and unlocking of keeper 24 as will be discussed in greater detail below with specific reference to FIGS. 3-7.

(31) Turning again to FIGS. 1 and 2, housing 22 includes an upstanding back wall 28 disposed opposite keeper 24 when keeper is in a closed position, bottom panel 30 and opposing upstanding side walls 32, 34 thereby defining an entry chamber 36 having a depth (D). See FIG. 3. Side walls 32, 34 may include flanges 32A, 34A for receiving a strike plate 38. See FIGS. 1, 2, 13-17. Side walls 32, 34 may also include apertures 40, 42 configured to receive pivot pin portions 44, 46, respectively. Apertures 40, 42 are positioned so as to coincide with a corresponding through bore 48 passing along a length of keeper 24 such that, upon insertion of pivot pin portions 44, 46, along with spring pin portion 50, keeper 24 is pivotally mounted onto housing 22 and rotatable about an axis X parallel with back wall (see FIG. 4). Spring pin portion 50 is configured to mount a biasing member such as coil spring 52 whereby the coil spring operates to bias keeper 24 toward the closed position, such as that shown in FIGS. 1, 3 and 4. Keeper 24 may further include an extendable face portion 54, integrated with keeper 24, which will be discussed in more detail below with regard to FIGS. 11 and 12. Leads 56 are connected at one end to an actuating device resident within actuator module 26 and extend outwardly from housing 22 wherein a second end 58 is connected to a power supply (not shown) so as to power the actuating device on demand.

(32) FIGS. 3 and 4 show various views of strike 20 with keeper 24 in the closed position and FIG. 5 shows the internal components of an exemplary embodiment 26 of an actuator module that may reside within housing 22. Generally, keeper 24 may include a notched portion 60 at the keeper end proximate through bore 48, the notched portion 60 is configured to engage a keeper release 62 slidably mounted within body 61 of actuator module 26. Keeper release 62, in turn, engages a keeper support 64 of actuator 69 also resident within actuator module 26. In this manner, the keeper is in the locked position such that any load placed on keeper 24 (such as an unauthorized attempt to open a door whose latch is secured within entry chamber 36 in the direction generally indicated by arrow 66FIG. 4) is transferred from the keeper through the release 62 to the keeper support 64 and ultimately to the back wall 28 of housing 22. A biasing member, such as a coil spring 67, operates to bias keeper release 62 into the extended, locked position shown in FIGS. 3-5.

(33) Referring now to FIG. 5, actuator module 26 includes keeper release 62 and actuator 69. Actuator 69, in turn, includes an actuating device 74, shown here as a solenoid, and an associated keeper support bracket 68 and keeper support 64. Keeper release 62 engages keeper support 64 which extends downwardly from keeper support bracket 68. Keeper support bracket 68 includes an actuator extension 70 that is configured to mount onto or otherwise engage plunger 72 of solenoid 74. In the case of a pull type solenoid operating in fail secure mode, actuation of solenoid 74 upon receiving power via leads 56 causes plunger 72 to be pulled into the body of solenoid 74 in the direction generally indicated by arrow 76. As keeper support bracket 68 is engageable with plunger 72 via actuator extension 70, the inward travel of plunger 72 results in a sliding travel of keeper support bracket 68 in direction 76, wherein keeper support bracket 68 may be slidably coupled with a guide 77 that is fixedly positioned relative to body 61. Keeper support 64 is likewise displaced by travel of keeper support bracket 68 such that keeper support 64 is no longer aligned with and operatively coupled to keeper release 62. With additional reference to FIGS. 6 and 7, at this point, any load on keeper 24 (such as an authorized attempt to withdraw a latch from entry chamber 36) operates to pivot keeper 24 about pin portions 44, 46, 50 so that keeper 24 drives keeper release 62 linearly, perpendicular to the axis X and/or toward back wall 28 of housing 22 against biasing member 67. Once any load on keeper 24 is removed (such as after the removal of the door latch), keeper 24 is returned to its locked position by biasing member 52 while keeper release 62 is returned to the extended position via biasing member 67. In this manner, once power to actuating device 74 has been withdrawn, plunger 72 may return to its original position, such as via a plunger return spring 78, to thereby return keeper support bracket 68 and keeper support 64 to their original positions whereby keeper support 64 is again aligned with and operatively coupled to keeper release 62 so as to lock keeper 24.

(34) As further shown in FIG. 5, actuator module 26 may include second keeper release 62a disposed at the opposite end of the module. Second keeper release 62a cooperates with second keeper support 64a of support bracket 68. In accordance with this aspect of the invention, the opposing forces imparted on the keeper when an unauthorized attempt is made to withdraw the latch from the entry chamber are balanced across the length of the keeper and translated evenly through first and second keeper releases 62,62a to the back wall of the housing.

(35) FIG. 8 shows an alternative actuator module 26, including actuator 69 and keeper release 62. Actuator 69 includes actuating device 74 such as a stepper motor, and keeper support bracket/support, 68, 64, respectively. As shown, keeper support 64 has been disengaged from keeper release 62 so as to allow pivoting of keeper 24 (not shown) to drive keeper release 62 rearwardly (keeper unlocked). To facilitate the sliding translation of keeper support 64, keeper support bracket 68 includes an actuator extension 70 configured to engage with rod 72 on stepper motor 74. Actuation of stepper motor 74 by a voltage having a first polarity causes rotation of shaft 80 so as to advance actuator extension 70 (and keeper support bracket 68 and keeper support 64) in one direction (such as the direction indicated by arrow 76) so as to cause disengagement of keeper support 64 from a rear surface of keeper release 62, such as, for example, shouldered notch 71 of keeper release 62. Supplying a voltage having the opposite polarity then reverses rotation of shaft 80 to advance actuator extension 70 in the opposite direction so as to cause engagement of keeper support 64 with shouldered notch 71. A biasing member, such as spring 78, may assist in driving actuator extension 70 in direction 76 toward stepper motor 74.

(36) As further shown in FIG. 8, actuator module 26 may include second keeper release 62a disposed at the opposite end of the module. Second keeper release 62a cooperates with second keeper support 64a of keeper support bracket 68. In accordance with this aspect of the invention, the opposing forces imparted on the keeper when an unauthorized attempt is made to withdraw the latch from the entry chamber are balanced across the length on the keeper and translated evenly through first and second keeper releases 62,62a to the back wall of the housing.

(37) An alternate embodiment of the actuator is shown in FIGS. 22-24 as actuator 269. Actuator 269 may include stepper motor 274, lead screw 280 of stepper motor 274, motor carrier 275, support bracket 268, including keeper support 264 and actuator extension 270, and a pair of opposing springs 277, 279 acting on support bracket 268. As seen in FIG. 23B, spring 277 may be disposed between a side wall 261a of body 261 and an outer surface of keeper support 264. Further, spring 279 may be disposed between an opposing side wall 261b of body 261 and an outer surface of keeper support 264. Springs 277 and 279 exert a combined force on support bracket 268 and collectively form biasing member 278. External threads 281 of lead screw 280 matingly engage internal threads 283 of motor carrier 275.

(38) Actuation of stepper motor 274 by supplying a voltage having a first polarity causes rotation of lead screw 280 so as to advance motor carrier 275 (and actuator extension 270 of keeper support bracket 268 that is in touching contact with motor carrier 275) in a first, keeper unlocking direction shown as arrow 276 in FIG. 23A. Stepper motor 274 may continue to drive towards the unlocked state (FIG. 23A) until a lock state switch 292 is depressed by, for example, an inner surface 294 of keeper support 264. Note that, in the keeper unlocked state, keeper support 264 is no longer aligned with and operatively coupled to keeper release 262. At this point, the keeper (not shown) is allowed to pivot and to release the latch as described above.

(39) Supplying stepper motor 274 a voltage having the opposite polarity reverses rotation of lead screw 280 to move motor carrier 275 in a second keeper locking direction opposite the first keeper unlocking direction. Upon movement of motor carrier 275 in the second keeper locking direction shown as arrow 282 in FIG. 23B, spring 277 biases actuator extension 270 against motor carrier 275 so as to move support bracket 268 in the second locking direction 282 as well. As shown in FIG. 23B, support bracket 268 has moved to the right (locking direction) so that keeper support 264 is aligned with and operatively coupled to keeper release 262, so as to prevent pivoting of the keeper (not shown) and to prevent release of the latch as described above. At this point, lock state switch 292 is released to indicate that the actuator 269 is in the locked state. If actuator 269 is unable to detect that the lock state switch 292 has been released and has failed to relock, stepper motor 274 may be configured to retry locking at a user configurable rate and/or duration. Further, a notification signal may be communicated, for example, wirelessly, to indicate to an access control system that actuator 269 is unsecure and failed to relock.

(40) As best shown in FIG. 23A, actuator 269 may include second keeper release 262 disposed at the opposite end of actuator 269. Second keeper release 262 may cooperate with second keeper support 264 of keeper support bracket 268.

(41) In the presently described embodiment, the spring constants of springs 277 and 279 are different and configured with respect to keeper support bracket 268 to provide equal but opposing forces on support bracket 268 so that when keeper support bracket 268 is in the position shown in FIG. 23B (keeper locked), the forces exerted by the two springs on keeper support bracket 269 are equal but opposing. At this point, since the forces are equal but opposing, the net lateral force on keeper support bracket 268 to oppose its movement in a direction to unlock the keeper is approximately zero.

(42) As best shown in FIG. 25, the lateral forces exerted on keeper support bracket 268 by springs 277 (line 286) and 279 (line 288) are indicated. In the example shown, when actuator 269 is in its locked state at point L (FIG. 23B), spring 277 is exerting a positive 14.0 g force in direction 282 to hold keeper support 264 in alignment with keeper release 262, At the same time, spring 279 is exerting a 14.0 g force in the opposite direction (direction 276 shown in FIG. 23A). This is represented as a negative 14.0 g force at point L (line 288 in FIG. 25). At point U in FIG. 25, actuator 269 has reached its unlocked state (FIG. 23A) wherein keeper support 264 is not aligned with and not operatively coupled to keeper release 262. In the example shown, spring 277 is exerting a positive 46.0 g force on keeper support 264 in direction 282 when keeper support 264 is in its unlocked state. At the same time, spring 279 is exerting a 9.0 g force on keeper support 264 in the opposite direction to hold actuator 269 in its unlocked state. This is represented as a negative 9.0 g at point U in FIG. 25. Line 290 represents the net lateral force imposed on keeper support bracket 268 by biasing member 278 (composite of springs 277 and 279) as support bracket 268 travels between its keeper locked position L and its keeper unlocked position U. As can be seen in FIG. 25, a 37.0 g force in direction 276 to be imposed by motor carrier 275 on actuator extension 270 in keeper unlocked position U.

(43) Importantly, the net lateral force exerted on support bracket 268 by biasing member 278 is zero in keeper locked position L. This provides for an increase in acceleration of support bracket 268 when actuator 274 is commanded to move the support bracket 268 in the unlocking direction to quickly release the latch from the keeper.

(44) Over time, it is further noted that the internal threads 283 of motor carrier 275 may wear causing the force needed by stepper motor 274 to rotate lead screw 280 and to move support bracket 268 away from position L to increase. The resulting sluggishness of movement of support bracket 268 to in the unlocking direction would counter the advantages bestowed by the embodiment including the dual springs 277, 279 discussed above. To reduce wear of the internal threads, motor carrier 285 may be molded of a wear resistant, high performance engineering plastic such as a polyether ether ketone polymer (PEEK).

(45) In accordance with the embodiment shown in FIGS. 22-25, a method of improving the performance of a strike actuator of an electric strike whereby the acceleration of the support bracket may be increased to quickly unlock the keeper is provided. The electric strike includes a stepper motor actuator, a keeper movable between a locked position and an unlocked position, and a support bracket movable by the stepper motor between a blocking position and an unblocking position. When the support bracket is in the blocking position the keeper is in the locked position, and when the support bracket is in the unblocking position the keeper is in the unlocked position. The method comprises the steps of: 1. providing a first spring operatively coupled to the support bracket to apply a first force in a first direction to move the support bracket toward the blocking position; 2. providing a second spring operative coupled to the support bracket to apply a second force in a second direction to move the support bracket toward the unblocking position, wherein a spring constant of the second spring is different than a spring constant of the first spring; 3. selecting the spring constants so that a net force exerted on the support bracket by the first and second springs is approximately zero when the support bracket is in the blocking position, whereby an acceleration of the support bracket is increased upon an initial movement of the support bracket toward the unblocking position.
A further step may include further selecting said spring constants so that a net force exerted on said support bracket by said first and second springs is approximately is positive in a direction to move said support bracket in its unblocking direction when said support bracket is in its unblocking position.

(46) In accordance with an aspect of the present invention, actuator module 26 may be configured to operate stepper motor 74 as a low power actuator. To that end, and with additional reference to FIGS. 9 and 10, actuator module 26 may further include a switching regulator 82, microcontroller 84, a constant-current constant-voltage (CCCV) regulator 86 and one or more super capacitors 88, such as model no. JUMT1474MED, supplied by Nichicon Corporation of Karasumadori Oike-agaru, Nakagyo-ku, Kyoto, 604-0845 Japan. When external power 90, such as a voltage ranging from about 10 VDC to about 30 VDC, is supplied to actuator module 26, on-board microcontroller 84 senses that power has been supplied (at time 92, FIG. 10) and drives the actuating device, such as stepper motor 74, from a first position to a second position using an actuator motor driver integrated circuit 94 (during time period 96, FIG. 10). After the actuator drive operation has completed, microcontroller 84 enables an onboard CCCV regulator 86 to charge on-board super capacitor(s) 88 (during time period 98, FIG. 10). After a fixed period of time microcontroller 84 disables CCCV regulator 86 (at time 100, FIG. 10). Once external power 90 is removed, microcontroller 84 may power the actuating device 74 using energy stored in super capacitor(s) 88. Actuating device 74 is then driven to return to the first position. In this manner, after charging of super capacitor(s) 88 has been completed, the power consumption of actuator module 22 is reduced. As a further benefit, the use of the controllable CCCV regulator allows for the peak current seen at an external supply output to be limited.

(47) As can be noted from the above, actuator module 26 may be selected to operate in either a fail safe mode or a fail secure mode depending on whether the first position has keeper support 64, 64 coupled to keeper release 62, 62 (fail secure) or whether the first position has members 62/64, 62/64 decoupled from one another (fail safe). To ensure that the actuator drive operation completes when a pre-load condition is present, a position sensor 95 may be used to supply the microcontroller with actuator position data. In one embodiment, position sensor 95 may be a contactless linear position Hall sensor in conjunction with a magnet. It should be understood that the position sensor may incorporate any suitable sensor system capable of sensing the actuator drive position, such as, but not limited to, a photo sensor, a pressure sensor, a micro switch, a passive infrared sensor, a radio frequency (RF) sensor, a reed switch, or the like. If microcontroller 84 determines the actuator drive was not successfully completed after receiving actuator position data from position sensor, microcontroller 84 will continue to drive the actuator until the desired position is successfully reached. To conserve power, position sensor 95 may be switched to a power down state when it is not being used.

(48) In accordance with a further aspect of the present invention, the actuating device may be a springless electromagnet actuator having a non-magnetic armature containing a permanent magnet combined with a solenoid body and coils similar to that disclosed within U.S. patent application Ser. No. 13/833,671. When using such a springless electromagnet actuator, microcontroller 84 can use input power 90 to provide a first pulse having a first polarity to drive the armature to the second position. Input voltage may then charge super capacitor(s) 88 through CCCV regulator 86 under microcontroller 84 control as described above. Once input power is removed, super capacitor(s) 88 may then provide the power needed for a second pulse having a second polarity to return the armature to the first position.

(49) While the actuating device has been described as either a solenoid, a stepping motor or a springless electromagnet actuator, it is understood the actuating device in accordance with the invention may include other types of motors, including a DC motor, or other types of powered actuating devices, including piezo electric and shape memory devices.

(50) Turning now to FIGS. 11 and 12, in accordance with an aspect of the present invention, keeper 24 may be configured to include an extendable face portion 54. Face portion 54 may be positionally adjusted to define the width of entry chamber 36 as measured between the outer face of face portion 54 and the inner surface of back wall 28 of housing 22 (such as from width W.sub.1 shown in FIG. 11 to width W.sub.2 shown in FIG. 12), thereby minimizing the gapped clearance between an extended latch and the width of the entry chamber.

(51) In accordance with this aspect, keeper 24 may include a groove 102 adapted to received face portion 54. One or more set screws 104 may be threadably inserted within corresponding threaded apertures 106 within face portion 54. Set screws 104 may be selectively advanced until the desire width is created, i.e., width W.sub.2. Groove 102 may include respective recesses 108 configured to receive a respective set screw 104. A fastener, such as hex screw 110 is then threaded through face portion 54 and into keeper 24 to secure face portion 54 to the keeper. Width W.sub.2 may be selected such there is little movement of the door latch, and subsequently the door, when the latch is locked within strike 20. Reduced movement minimizes unnecessary wear and tear on the latch and the strike, as well as reduces door movement and subsequent noise. In addition, when used in conjunction with a cylindrical-type lockset, and when extendable face portion 54 is adjusted outward and keeper 24 is in its locked position as shown in FIG. 12, surface 111 of extendable face portion 54 may serve as a resting platform for the dead latch of the lockset when the associated latch is received by entry chamber 36. Thus, extendable face portion 54 provides additional assurance that the dead latch remains retracted when the cylindrical lockset is in a locked position, thereby preventing an unauthorized forced retraction of the associated latch to unlock the door. Provision of set screws 104 enables fine incremental control of the placement of face portion 54 over a wide range of entry chamber widths without requiring multiple shim members which are presently employed within the art. Further, in the prior art, a shim pack was provided with the strike product so that, at the time of installation, the width of the entry chamber could be varied as needed, by the selection and installation of the appropriate sized shim to the face of the keeper. However, over time, through usage of the door, the width of the entry chamber can be expected to change, requiring a different sized shim to take up the gapped clearance. Often, the shim pack would be discarded after original strike installation so that a later re-adjustment of the gapped clearance could not be made. In accordance with the invention, the means for re-adjusting the gapped clearance remains with the strike so that re-adjustments can be conveniently made at any time after original installation.

(52) FIGS. 13-15 show additional features that may be included with strike 20. For instance, as shown in FIG. 13, strike 20 may be configured to house one or more latch bolt monitors (LBM) 112, which may also be interchangeable across a multitude of electric strike models. LBM 112 may be secured to housing 22 of strike 20 by way of screws or other fasteners inserted through holes 114 defined within back wall 28 of housing 22 (see FIG. 2). Back wall 28 may also include apertures 116 through which wires associated with LBM 112 may be passed for proper operation of LBM 112.

(53) FIG. 14 shows an optional trim plate 118 that may be placed around keeper 24 when strike 20 is mounted to the door frame. Trim plate 118 may be mounted directly to frame 120 or to housing 22. Trim plate 118 may be used to improve aesthetics or may be used to cover any small gaps or cracks between strike 20 and the underlying frame 120.

(54) As seen in both FIGS. 13 and 14, strike 20 may include a strike plate 38 configured to rest against flanges 32A and 34A of respective side walls 32, 34 of housing 22. Strike plate 38 may be mounted to frame 120 via screws 122. As shown in FIG. 15, strike 20 may be configured to receive one of any number of various strike plates, such as anyone of strike plates 38A-38E, depending on the type of latch system mounted onto the door, including a cylindrical-type lockset (see FIG. 38C, for example).

(55) As shown in FIGS. 16 and 17, strike 20 may further include an open-sided deadbolt bracket 124 comprising, for example, a rear wall 128, a bracket side wall 131, and a front wall 134, which is proportioned to receive a deadbolt (not shown), wherein a distal ends 133, 135 of bracket 124 may abut side wall 34 of housing 22, and bracket 124 and side wall 34 conjunctively define a walled deadbolt receiving chamber 123 having a vertical length 129. In the prior art, the end of the deadbolt bracket is not open but, instead, includes an end wall that is generally the thickness 125 of the bracket and abuts with side wall 34 of housing 22 when the deadbolt bracket is assembled into housing 22. Thus, in the prior art, the vertical length the deadbolt receiving chamber is reduced by the added thickness 125 of the bracket abutting side wall 34. In some cases, the reduced vertical length of the receiving chamber of a prior art deadbolt bracket interferes with an extended deadbolt, thereby preventing full engagement of the deadbolt in the strike, or preventing compatibility of the strike with some dead bolts.

(56) Deadbolt bracket 124 in accordance with the invention may be mounted within housing 22 by a pair of screws 126 passing through holes 114 define within back wall 28 of the housing and threaded into corresponding holes 127 defined in rear wall 128 of deadbolt bracket 124. Side wall 34 may include a slot 130 configured to receive a tab 132 extending from an end 135 of front wall 134 of deadbolt bracket 124. In this manner, deadbolt bracket 124 is rigidly secured along two faces of housing 22 such that any load placed on the deadbolt latch (not shown) impacts the deadbolt bracket and housing 22 and not keeper 24.

(57) Thus, the deadbolt receiving chamber 123 of open-sided deadbolt bracket 124 provides more room and greater vertical clearance for the associated deadbolt and, if keeper 24 were to be compromised or otherwise fail, the door would remain secure due to the deadbolt securely residing within receiving chamber 123 of deadbolt bracket 124. In addition, deadbolt bracket 124 may also be made to be interchangeable across a multitude of electric strike models. While deadbolt bracket is shown as being U-shaped in FIGS. 16 and 17, it should be understood that deadbolt bracket is not necessarily limited to this specific shape. Further, in another aspect, the open ended portion of deadbolt bracket 124 could also be oriented so that it abuts back wall 28 of housing 22 instead of side wall 34 of housing 22.

(58) FIGS. 18 and 19 show a typical mortise lockset 140 (FIG. 19) and a typical electric strike 160 (FIG. 18) in the prior art. Mortise lockset 140 includes latch 142 and dead latch 144 linearly spaced-apart from latch 142. Latch 142 may be a spring latch having tapered contact face for making initial contact with the keeper when the door is moved to its closed position. Dead latch 144 is reciprocally moveable between an enabling position (extended, as shown) that permits movement of the latch from its extended engaged position (as shown) to a released position, and a disabling position that prohibits movement of the latch from its engaged position to its released position. It is well known in the art that, as a door is moved to a closed position and dead latch 144 begins initial contact with an associated strike plate, latch 142 (FIG. 18) must begin to move from its extended position and toward its release position before dead latch 144 moves away from its enabling (extended) position. If the dead latch is caused to move away from its extended position first, it will prohibit movement of the latch toward its released position, thereby blocking the latch from properly entering strike cavity 168 (and preventing the door from latching).

(59) Referring to FIG. 18, prior art electric strike 160 includes a housing 162 having side walls 32, 34, a prior art deadbolt receiving chamber 123 for receiving an extendable dead bolt (not shown), and a longitudinal length 161. Side walls 32, 34 include edge 170 comprising front edge 172, top edge 174 and front profile 176 joining front edge 172 and top edge 174 to form continuous edge 170. Prior art electric strike 160 also includes a pivotable keeper 164 (shown in a locked position), having a contoured surface 166 running the longitudinal length 178 of the keeper, wherein the entire length of contoured surface 166 resides between side walls 32, 34. Keeper 164 pivots about pivot pin 44 about axis of rotation X (FIG. 3). Also included in electric strike 160 is receiving cavity 168 for receiving latch 142 when the door is closed. As can be seen, with a proper door to door frame alignment, and therefore a proper vertical alignment of the latch and dead latch relative to cavity 168, both the latch and dead latch will make contact with contoured surface 166 and will cause a proper sequencing of the retraction of the latch followed by the retraction of the dead latch. However, with an improper alignment, such as might be caused by a sagging door, the dead latch 144 may not make contact with contoured surface 166 and may instead contact edges 172 or 174, or front profile 176 of edges 170 before latch 142 makes contact with contoured surface 166. As a result, latch 142 is prohibited from moving toward its released position, thereby blocking the latch from entering cavity 168 and preventing the door from latching.

(60) Referring now again to FIGS. 13, 16 and 17, in another aspect of the invention, keeper 24 may include a ramp element 23 and a keeper base 27, wherein ramp element 23 may include a contoured surface 33 that is contactable by a spring latch and/or dead latch of a lockset as the door is moved to a closed position. In this aspect, with additional reference to FIG. 3, contact surface 33 may extend a distance (A) beyond a front profile 41 of housing 22 when keeper 24 is in the locked position to prevent the spring latch and/or dead latch from contacting housing 22 or frame 120 as the door is moved to the closed position. For example, contact surface 33 may extend distance (A) beyond a front edge 43 of at least one of side walls 32, 34 when keeper 24 is in the locked position to prevent the spring latch and/or dead latch from contacting housing 22 or frame 120 as the door is moved to the closed position. Further, at least a portion of a profile 45 of contact surface 33 may be configured to match at least a portion of front profile 41 of housing 22, for example, the profile of front edge 43 of at least one of side walls 32, 34. While profile 45 of contact surface 33 is shown as being rounded, it should be understood that other profiles are also contemplated herein.

(61) In yet another aspect of the invention, keeper 24 may optionally include at least one extension flange 29 that projects from an end of ramp element 23 that extend beyond at least one of side edges 25 of keeper base 27. When keeper 24 is in a locked position ((FIG. 13), extension flange 29 covers front edge 43 of a respective side wall 32, 34 so that a misaligned spring latch or dead latch will contact ramp element 23 instead of front edge 43, such as, for example, a corner of housing 22. To that extent, front edge 43 of side walls 32, 34 may be contoured to accept the underside of extension flange 29 of ramp element 23 so that a top portion 37 of contact surface 33 of keeper 24 may be essentially flush with a top surface 39 of strike plate 38 mounted to strike (FIG. 3).

(62) Several aspects of this invention have been disclosed as being desirably interchangeable across a multiple of electric strike models, thereby demonstrating the versatility of the disclosed electric strike and its ability to meet various strike needs. In another aspect of the invention, a strike lip extension can be used with the disclosed electric strike in order to make the electric strike adaptable to fit a variety of door frames that might exist in the field. Referring to FIGS. 20A, 20B and 21, U-shaped lip extension 180 may be used in conjunction with actuator controlled electric strike 20, shown in FIG. 1, when an existing door frame cut-out is wider than the a standard cut-out width.

(63) Referring to FIG. 20A, electric strike 20 and strike plate 38A are shown mounted in cut out 119 of a standard width door frame 120 designed to receive a standard 1 inch thick door. As can be seen in this figure, keeper 24 is in its locked position and rounded edge 166 of keeper 24 is in close alignment with edge 121 of the door frame. Referring now to FIG. 20B, the same electric strike 20 and strike plate 38A are mounted in cut out 119 of a door frame 120 having surface 182 of door frame 120 wider that the width of surface 182 shown in FIG. 20A. In conjunction with the wider door frame and wider cut out shown in FIG. 20B, edge 184 of strike plate 38A is disposed a greater distance 186 from surface 121 of the door frame than the edge 184 of strike plate 38A is disposed from surface 121 in FIG. 20A (see dimension 186). To close out the gap 190 between electric strike 20 and frame surface 121 caused by the larger cut out 119, lip extension 180 is provided.

(64) Referring now to FIG. 21, housing 20 of strike 22 includes a notch 192 that may run the entire length of housing 20. U-shaped lip extension 180 includes bottom panel 181 and side wings 183 extending from opposite ends of bottom panel 181 and formed at right angles to bottom panel 181 to form the U-shape. Rib 193, which may have a square or rectangular cross-section, is disposed on the bottom panel 181 and extends between side wings 183. Notches 185 are formed on the leading corners of side wings 183. The notches 185, rib 193 and length of side wings 183 are configured so that, when lip extension 180 is fitted and mounted to strike 22, the inside surface of bottom panel 181 fits closely and is adjacent to the bottom surface 21 of housing 22, notches 185 fit closely and are adjacent to strike plate 38A and housing flanges 32A, 34A, and rib 193 fits closely and adjacent to notch 192 of housing 20. Alignment holes 187 (2 of 3 shown), formed within notch 192, receive mating pegs (not shown) formed in a leading edge of bottom panel 181 to aid in further alignment of the lip extension to the strike housing. Fasteners 191, such as screws, are used to secure the lip extension to the housing. As can be seen in FIG. 20B, when electric strike 20 is then secured to door frame 120, a neat package is created whereby gap 190 is entirely concealed by U-shaped extension 180.

(65) In accordance with a further aspect of the present invention, a method for locking or unlocking a door having an actuator-controlled electric strike for operating in conjunction with a latch of a lockset is included, wherein the latch has an engaged position so as to secure a door in a closed state and a released position, and wherein the strike includes a housing including a back wall and opposing side walls and defining an entry chamber therein; a keeper rotatably disposed hi the entry chamber about an axis for rotation between a locked position and a unlocked position; and an actuator module, including a keeper release configured to engage the keeper, and an actuator selectively movable between a first actuator position and a second actuator position, wherein when the actuator is in one of the first or second actuator positions the keeper release is coupled to the keeper and the keeper is secured in the locked position, and wherein when the actuator is selectively moved to the other of the first or second actuator positions the keeper release is decoupled from the keeper and the keeper is rotatable to the unlocked position, the method for unlatching comprising the steps of providing an input voltage to drive the actuator from a first position to a second position; after driving the actuator, using the input voltage to charge a capacitor; removing the input voltage; and providing a return voltage via the capacitor to drive the actuator from the second position to the first position.

(66) The method may further include the actuator module having a microcontroller wherein the microcontroller senses an input polarity of the input voltage and drives the actuator from the first actuator position to the second actuator position. Further, the capacitor may be a super capacitor wherein the actuator module further includes a constant-current, constant-voltage (CCCV) charger, the microcontroller controlling the CCCV charger to charge the super capacitor after the actuator has been driven to the second actuator position, the super capacitor then providing a second voltage having a polarity opposite the input polarity to drive the actuator from the second actuator position to the first actuator position.

(67) A method for changing an actuator module of a strike assembly is provided wherein said actuator module is a first actuating module including an actuator and a keeper release, comprising the steps of: 1) providing said strike assembly having said first actuator module disposed in a strike assembly housing wherein said housing includes a movable keeper, wherein the first actuator module includes a first actuating device comprising one of a solenoid or a motor, and further comprising a first keeper release operatively engageable with said movable keeper to selectively release said keeper from a locked position to a released position; 2) allowing for the removal of said first removable actuator module from said housing; and 3) allowing for the installation of a second removable actuator module in place of said first removable actuator module wherein the second actuator module includes a second actuating device comprising one of a solenoid or a motor, and further comprising a second keeper release operatively engageable with said movable keeper to selectively release said keeper from a locked position to a released position.

(68) While the invention has been described by reference to various specific embodiments, it should be understood that numerous changes may be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention not be limited to the described embodiments, but will have full scope defined by the language of the following claims.