A MAIN HOUSING PART OF A LOCK HOUSING, A LOCK HOUSING AND A METHOD FOR MANUFACTURING A HOUSING PART

Abstract

 A main housing part (1) of a lock housing (3) configured for mounting in a door or a window is described. The main housing part (1) comprises an outer casing (5) and a number of housing parts (7) arranged within the outer casing (5) and in the outer casing (5) and being configured for at least mounting of a number of lock mechanism elements of a lock mechanism (9) in the main housing part (1) and for attachment of a lid part (11) of the lock housing (3) to the main housing part (1) and for mounting of the main housing part (1) with the lid part (11) in the door or the window. The main housing part (1) comprising the outer casing (5) and the number of housing parts (7) is a one-piece main housing part (1) manufactured by a Metal Injection Molding (MIM) Process comprising a step of injecting a metal into a mold configured to achieve the one-piece main housing part (1). A lock housing (3) and a method are also described.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a main housing part of a lock housing configured for mounting in a door or a window. The present disclosure further relates to a lock housing comprising a main housing part and a lid part and to a method for manufacturing a housing part of a lock housing.

BACKGROUND

[0002] Lock devices for doors and windows, etc. have in many cases a handle or knob by which parts incorporated in the lock, such as a latch bolt and other bolts, are directly actuated by way of a follower disposed in the lock device. In many cases, a spring-back function of the follower is desired, so that the handle or the knob regains an original position following, for example, manoeuvring of the lock. Electronic lock devices are activated by a current and access is controlled by an electrical impulse. Depending on the electric lock chosen, it can be triggered by a key fob, a key card or by typing in an access code activating a solenoid, electromagnet or a motor of a lock mechanism of the lock device. The electrical impulse allows the user to operate a mechanically connected handle.

[0003] A lock device comprises a lock housing in which a lock mechanism is mounted. Today punched sheet metal is mostly used for lock housings with punched openings, mounted axles, spacers and other elements for mounting of a lock mechanism and for attachment purposes.

[0004] Although today methods for manufacturing of lock housings work well, by applying their detailed knowledge in the area of manufacturing of lock housings, the inventors have identified some problems and drawbacks with methods used today and have identified and realized new improvement areas of manufacturing that are important i.a. for efficiency of assembling lock housings and lock mechanisms and for reliable functioning of a lock mechanism mounted in a lock housing.

SUMMARY

[0005] It is an object of the present invention to overcome, or at least alleviate, at least some of the above-mentioned problems and drawbacks.

[0006] According to a first aspect of the invention, the object is achieved by a main housing part of a lock housing configured for mounting in a door or a window. The main housing part comprises an outer casing and a number of housing parts arranged within the outer casing and in the outer casing and being configured for at least mounting of a number of lock mechanism elements of a lock mechanism in the main housing part and for attachment of a lid part of the lock housing to the main housing part and for mounting of the main housing part with the lid part in the door or the window.

[0007] The housing parts as referred to herein refer to a number of openings in the outer casing, to a number of axles and other positioning parts for positioning and mounting of the lock mechanism elements in the main housing part, and to attachment parts configured for attachment of the lid part to the main housing part and for attachments of the lock housing to a door or a window.

[0008] The main housing part is sometimes referred to as a bottom part of a lock housing.

[0009] The main housing part comprising the outer casing and the number of housing parts is a one-piece main housing part manufactured by an Injection Molding (IM) Process comprising a step of injecting a material into a mold configured to achieve the one-piece main housing part. Thus, the whole main housing part with the number of housing parts is the one-piece main housing part. The housing parts are not attached to the outer casing afterwards after the outer casing has been manufactured. Further, the housing parts are not drilled or sown in the outer casing afterwards after the outer casing has been manufactured.

[0010] Historically, some parts of a locking device could be manufactured by an Injection Molding (IM) Process. However, the inventors have developed and tested an IM Process that works for manufacturing of a whole main housing part with all the housing parts as a one-piece main housing part. Thus, the main housing part can be manufactured as a one-piece main housing part by using an IM process comprising a step of injecting a material into a mold configured to achieve the one-piece main housing part.

[0011] This is a completely new way of manufacturing a main housing part which results in an improved main housing part having several advantages.

[0012] One advantage is that assembling of housing parts, as explained above, in an outer casing of a main housing part is not longer needed. This contributes to saving time and lowering costs for manufacturing of main housing parts. Further, it enables manufacturing of several main housing parts where all main housing parts are substantially the same. Deviations between manufactured main housing parts that are at least reduced facilitates mounting of lock mechanisms in the main housing parts. Further, reliability of the functioning of a locking device mounted in a lock housing may be improved. Moreover, fastening of a lid part and fastening to a door or a window is facilitated. Further, a main housing part manufactured as a one-piece main housing part by using an IM process may be advantageable with respect to the strength of the main housing part.

[0013] Accordingly, an improved main housing part is provided. Thus, a main housing part is provided having conditions to at least alleviating, at least some of the above-mentioned problems and drawbacks. As a result, the above-mentioned object is achieved.

[0014] The Injection Molding (IM) Process is a Metal Injection Molding (MIM) Process and wherein the material injected into the mold is a metal. Thereby, the main housing part may be manufactured of a metal with all the advantages as described above regarding the one-piece main housing part.

[0015] Optionally, the main housing part comprises a front attachment part integrated with the main housing part and thereby with the outer casing. The front attachment part is configured for attachment of the lock housing to the door or the window. The main housing part comprising the outer casing and the front mounting part and the number of housing parts is a one-piece main housing part and may be referred as a further one-piece main housing part.

[0016] Thus, a further main housing part with a front attachment part integrated with the main housing part as a further one-piece main housing part is provided. Thus, attachment of the front attachment part to the outer casing, as it is done today, is not needed.

[0017] According to a second aspect of the invention, the object is achieved by a lock housing comprising a main housing part according to some embodiments described herein and a lid part configured to be attached to the main housing part to enclose a lock mechanism mounted in the main housing part.

[0018] Since the lock housing comprises an improved main housing part according to some embodiments, a lock housing is provided overcoming, or at least alleviating, at least some of the above-mentioned problems and drawbacks. As a result, the above-mentioned object is achieved.

[0019] Optionally, the lid part is a one-piece lid part manufactured by an Injection Molding (IM) Process comprising a step of injecting a material into a mold configured to achieve the one-piece main lid part. Thus, an improved one-piece lid part is provided.

[0020] Optionally, the Injection Molding Process (IM) for the lid part is a Metal Injection Molding Process (MIM) and wherein the material injected into the mold is a metal. Thereby, the lid part may be manufactured of a metal.

[0021] According to a third aspect of the invention, the object is achieved by a method for manufacturing a housing part of a lock housing configured for mounting in a door or a window. The method comprises the step of:
performing an Injection Molding (IM) Process comprising a step of injecting a material into a mold configured to achieve the housing part as a one-piece housing part.

[0022] This is a completely new way of manufacturing a housing part resulting in an improved housing part having several advantages, such time saving for assembling. Further, a housing part manufactured as a one-piece housing part by using an IM process may be advantageable with respect to the strength of the housing part.

[0023] The Injection Molding (IM) Process is a Metal Injection Molding (MIM) Process and wherein the material injected into the mold is a metal. Thereby, a metal may be used in the method and the main housing part may be manufactured of the metal with all the advantages as described above regarding the one-piece main housing part.

[0024] The housing part is a main housing part comprising an outer casing and a number of housing parts arranged within the outer casing and in the outer casing and being configured for at least mounting of a number of lock mechanism elements of a lock mechanism in the main housing part and for attachment of a lid part of the lock housing to the main housing part and for mounting of the main housing part with the lid part in the door or the window.

[0025] As a result, assembling of the housing parts, in an outer casing of a main housing part is not longer needed. This contributes to saving time and lowering costs for manufacturing of main housing parts. Further, it is enabled to manufacture several main housing parts where all main housing parts are substantially the same. Deviations between manufactured main housing parts that are at least reduced facilitates mounting of lock mechanisms in the main housing parts. Further, reliability of the functioning of a locking device mounted in a lock housing may be improved. Moreover, fastening of a lid part and fastening to a door or a window is facilitated. Further, a main housing part manufactured as a one-piece main housing part by using an IM process may be advantageable with respect to the strength of the main housing part.

[0026] Optionally, the main housing part comprises a front attachment part integrated with the main housing part and thereby with the outer casing. The front attachment part is configured for attachment of the lock housing to the door or the window. The main housing part comprising the outer casing and the front mounting part and the number of housing parts is a one-piece main housing part that may be referred as a further one-piece main housing part. The method comprises the step of: performing a Metal Injection Molding (MIM) Process comprising a step of injecting a metal into a mold configured to achieve the further one-piece main housing part as a one-piece main housing part. Thus, a further main housing part with a front attachment part integrated with the main housing part as a further one-piece main housing part can be provided by using the method. Thus, attachment of the front attachment part to the outer casing, as it is done today, is not needed.

[0027] Optionally, the housing part is a lid part configured to be attached to a main housing part to enclose a lock mechanism mounted in the main housing part. Thus, an improved one-piece lid part can be provided by the method.

[0028] Further features of, and advantages with, the present invention will become apparent when studying the appended claims and the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Various aspects of the invention, including its particular features and advantages, will be readily understood from the example embodiments discussed in the following detailed description and the accompanying drawings, in which:

Fig. 1 illustrates a lock housing in a first view with a main housing part and a lid part separated from each other according to some embodiments,

Fig. 2 illustrates the lock housing illustrated in Fig. 1 in a second view,

Fig. 3 illustrates the lock housing illustrated in Fig. 1 and Fig. 2 with the lid part connected to the main housing part in a position for attachment of the lid part to the main housing part,

Fig. 4 illustrates a lock device with a front part integrated with a main housing part and with a lock mechanism mounted in the main housing part according to some embodiments, and

Fig. 5 is a flow diagram illustrating a method according to the invention.

DETAILED DESCRIPTION

[0030] Aspects of the present invention will now be described more fully. Like numbers refer to like elements throughout. Well-known functions or constructions will not necessarily be described in detail for brevity and/or clarity.

[0031] Fig. 1 illustrates a lock housing 3 in a first view with a main housing part 1 and a lid part 11 separated from each other according to some embodiments. The lock housing 3 is configured for mounting in a door or a window.

[0032] The main housing part 1 comprises an outer casing 5 and a number of housing parts 7 arranged within the outer casing 5 and in the outer casing 5 and being configured for at least mounting of a number of lock mechanism elements of a lock mechanism 9 in the main housing part 1 and for attachment of a lid part 11 of the lock housing 3 to the main housing part 1 and for mounting of the main housing part 1 with the lid part 11 in the door or the window.

[0033] The housing parts 7 as referred to herein refer to a number of openings 7 in the outer casing 5, to a number of axles 7 and other positioning parts 7 for positioning and mounting of the lock mechanism elements in the main housing part 1, and to attachment parts 7 configured for attachment of the lid part 11 to the main housing part 1 and for attachments of the lock housing 3 to a door or a window.

[0034] In Fig. 1 only some of the housing parts 7 have the reference 7, however the housing parts 7 refer to all the housing parts 7 illustrated in Fig. 1.

[0035] As illustrated in Fig. 1, the main housing part 1 comprising the outer casing 5 and the number of housing parts 7 is a one-piece main housing part 1 manufactured by an Injection Molding (IM) Process comprising a step of injecting a material into a mold configured to achieve the one-piece main housing part 1.

[0036] The one-piece main housing part 1 has several advantages. One advantage is that assembling of housing parts 7, in the outer casing 5 of the main housing part 1 is not longer needed. What is meant with the housing parts 7 has been explained above. Thus, no one of the housing parts 7 needs to be attached to the outer casing 5 afterwards after the outer casing 5 has been manufactured. Further, no one of the housing parts 7 needs to be drilled or sown in the outer casing 5 afterwards after the outer casing 5 has been manufactured. This contributes to saving time and lowering costs for manufacturing of main housing parts 1.

[0037] Further, it is enabled to manufacture several main housing parts 1 where all main housing parts 1 are substantially the same. Deviations between manufactured main housing parts 1 that are at least reduced facilitates mounting of lock mechanisms in the main housing parts 1. Further, reliability of the functioning of a locking device mounted in the lock housing 3 may be improved. Moreover, fastening of a lid part 11 and fastening to a door or a window is facilitated. Further, a main housing part 1 manufactured as a one-piece main housing part 1 by using an IM process may be advantageable with respect to the strength of the main housing part. Today some housing parts 7, such as axles 7, need to be attached to the outer casing by means of, for example screws, bolts, pressings, weldments or rivets. According to the invention no attachments are needed and thereby risks for weakening of the connections present according to ways used today are at least reduced. This because there are no connections in the main housing part 1.

[0038] Injection Molding (IM) Process is known per sig in the art and is a manufacturing process for producing parts by injecting molten material into a mold. The IM Process is therefore not described in details herein. However, the inventors have developed an IM Process that enables manufacturing of housing parts of a lock housing, i.a. a main housing part as one-piece housing parts which is new in the art. The material may be a plastic material.

[0039] The illustrated lock housing 3 is preferably designed for an electronic locking device and the main housing part 1 is designed to accommodate lock mechanism elements of an electronic lock mechanism 9. However, the one-piece main housing part 1 may be designed for different kinds of locking devices, such as for example mechanical locking devices. Modern locking devices usually comprise several advanced components that require several advanced housing parts 7. The claimed invention facilitates manufacturing of modern locking devices.

[0040] According to the invention, the one-piece main housing part 1 is manufactured by a Metal Injection Molding (MIM) Process and the material injected into the mold is a metal.

[0041] Metal Injection Molding (MIM) Process is known per sig in the art and is a metalworking process in which finely-powdered metal is mixed with binder material to create a "feedstock" that is then shaped and solidified using injection molding. The MIM Process is therefore not described in details herein. However, the inventors have developed an MIM Process that enables manufacturing of housing parts of a lock housing, i.a. a main housing part as one-piece housing parts which is new in the art. Different metals may be used. Preferably, the metal is steel, for example, stainless steel.

[0042] The lock housing 3 comprises a lid part 11 configured to be attached to the main housing part 1 to enclose a lock mechanism mounted in the main housing part 1. As illustrated in Fig. 1, the lid part comprises holes for screws to enable an attachment of the lid part 11 to the main housing part 1.

[0043] Preferably, the lid part 11 is a one-piece lid part 11 manufactured by an Injection Molding (IM) Process comprising a step of injecting a material into a mold configured to achieve the one-piece main lid part 11. Yet preferably, the lid 11 is manufactured by a Metal Injection Molding (MIM) Process and the material injected into the mold is a metal. The IM and MIM Processes and materials are described above.

[0044] According to the illustrated embodiments the lid part 11 is designed as a flat sheet part 11. However, the main housing part and the lid part can also be configured to be split in half along a center plane of the lock housing, thereby forming two main housing bodies with integrated lid panels.

[0045] Fig. 2 illustrates the lock housing 3 illustrated in Fig. 1 in a second view to better illustrate the housing parts 7 of the one-piece main housing part 1.

[0046] Fig. 3 illustrates the lock housing 3 illustrated in Fig. 1 and Fig. 2 with the lid part 11 connected to the main housing part 1 in a position for attachment of the lid part 11 to the main housing part 1.

[0047] Fig. 4 illustrates a lock device 4 with a front part 2 integrated with a main housing part 1' and with a lock mechanism 9 mounted in the main housing part 1' according to some embodiments. In Fig. 4 only a few lock mechanism elements of the lock mechanism 9 are visible.

[0048] Thus, according to some embodiments also the front attachment part 2 may be integrated with the main housing part 1 by being manufactured directly together with the main housing part by using an IM Process, preferably MIM Process. Thus, a further main housing part 1 may be provided. As a result, the main housing part 1' comprising the outer casing 5 and the front mounting part 2 and the number of housing parts 7 is a further one-piece main housing part 1'.

[0049] The front attachment part 2 is configured for attachment of the lock housing 3 to the door or the window.

[0050] The further main housing part 1' and the lid part 11 form a further lock housing 3'.

[0051] The present invention also relates to a method for manufacturing a housing part 1, 1', 11. The housing parts 1, 1', 11 have been described in detail above and it is herein referred to that description. The method will now be described with references to the flow diagram shown in Fig. 5.

[0052] In the following, some embodiments of the method are listed. These have the same technical features and advantages as for the corresponding features of the housing parts 1, 1', 11 described above. Consequently, these technical features and advantages are not repeated or explained anew in order to avoid unnecessary repetition.

[0053] The method comprises the step of:
performing an Injection Molding (IM) Process comprising a step of injecting a material into a mold configured to achieve a housing part 1, 1' 11 as a one-piece housing part 1, 1', 11.

[0054] Optionally, the Injection Molding (IM) Process is a Metal Injection Molding (MIM) Process and wherein the material injected into the mold is a metal.

[0055] The present invention is not limited to the above-described preferred embodiments. Various alternatives, and modifications may be used. Therefore, the above embodiments should not be taken as limiting the scope of the invention, which is defined by the appending claims.

Claims

1. A main housing part (1, 1') of a lock housing (3, 3') configured for mounting in a door or a window, the main housing part (1, 1') comprises an outer casing (5) and a number of housing parts (7) comprising at least a number of openings in the outer casing (5) and a number of axles and positioning parts and attachment parts, wherein the housing parts (7) are arranged within the outer casing (5) and in the outer casing (5) and being configured for at least mounting of a number of lock mechanism elements of a lock mechanism (9) in the main housing part (1, 1') and for attachment of a lid part (11) of the lock housing (3, 3') to the main housing part (1, 1') and for mounting of the main housing part (1, 1') with the lid part (11) in the door or the window,
characterized in that
the main housing part (1, 1') comprising the outer casing (5) and the number of housing parts (7) is a one-piece main housing part (1, 1') manufactured by a Metal Injection Molding (MIM) Process comprising a step of injecting a metal into a mold configured to achieve the one-piece main housing part (1, 1 '), wherein the whole main housing part (1, 1') with the number of housing parts (7) is the one-piece main housing part (1, 1').

2. The main housing part (1') according to claim 1, comprising a front attachment part (2) integrated with the main housing part (1 '), wherein the front attachment part (2) is configured for attachment of the lock housing (3') to the door or the window, and wherein the main housing part (1') comprising the outer casing (5) and the front mounting part (2) and the number of housing parts (7) is a one-piece main housing part (1').

3. A lock housing (3, 3') comprising a main housing part (1, 1') according to any one of claims 1 to 2 and a lid part (11) configured to be attached to the main housing part (1, 1') to enclose a lock mechanism (9) mounted in the main housing part (1, 1').

4. The lock housing (3, 3') according to claim 3, wherein the lid part (11) is a one-piece lid part (11) manufactured by a Metal Injection Molding (MIM) Process comprising a step of injecting a metal into a mold configured to achieve the one-piece main lid part (11).

5. A method for manufacturing a main housing part (1, 1') of a lock housing (3, 3') configured for mounting in a door or a window, wherein the main housing part (1, 1') comprises an outer casing (5) and a number of housing parts (7) comprising at least a number of openings in the outer casing (5) and a number of axles and positioning parts and attachment parts, wherein the housing parts (7) are arranged within the outer casing (5) and in the outer casing (5) and being configured for at least mounting of a number of lock mechanism elements of a lock mechanism (9) in the main housing part (1, 1') and for attachment of a lid part (11) of the lock housing (3) to the main housing part (1, 1') and for mounting of the main housing part (3, 3') with the lid part (11) in the door or the window.
characterized in that
the method comprises the step of:
performing a Metal Injection Molding (MIM) Process comprising a step of injecting a material into a mold configured to achieve the main housing part (1, 1') as a one-piece housing part (1, 1 '), wherein the whole main housing part (1, 1') with the number of housing parts (7) is achieved as the one-piece main housing part (1, 1').

6. The method according to claim 5, wherein the main housing part (1') comprises a front attachment part (2) integrated with the main housing part (1 '), wherein the front attachment part (2) is configured for attachment of the lock housing (3') to the door or the window, and wherein the main housing part (1') comprising the outer casing (5) and the front mounting part (2) and the number of housing parts (7) is a one-piece main housing part (1').

Drawing