Interconnected lock with direct drive for adjustable deadbolt to latchbolt spacing

Abstract

An interconnected lock for use on a door, where the lock has adjustable offset spacing between a deadbolt and latchbolt. The lock includes first and second shafts for actuating the deadbolt lock mechanism, at different offset spacings. A linkage arm connected to and moveable by the latchbolt actuator is alternately connectable to rotate either the first or second deadbolt-actuating shaft. The linkage arm has first and second upper positions, for alternate connection to rotate the first and second deadbolt-actuating shafts, respectively. Upon operation of the interior actuator, the linkage arm moves the deadbolt along the second axis from the latched to the unlatched position at the same time that the operation of the interior actuator moves the latchbolt along the first axis from the latched to the unlatched position.

Claims

1. An interconnected lock for use on a door, where the lock has adjustable offset spacing between a deadbolt and a latchbolt, comprising: a latchbolt mechanism mountable in a first bore through a door and including the latchbolt and an interior actuator operable to move the latchbolt between latched and unlatched positions along a first axis; a deadbolt lock mechanism mountable in a second bore through the door, the second bore being spaced from the first bore, the deadbolt being moveable by the deadbolt lock mechanism along a second axis between latched and unlatched positions, a distance between the first axis and the second axis defining the offset spacing, the offset spacing being adjustable between a first offset spacing from the first axis and a second, greater offset spacing from the first axis; first and second shafts for actuating the deadbolt lock mechanism, the first shaft being disposed at the first offset spacing from the first axis and the second shaft being disposed at the second, greater offset spacing from the first axis; and a driver member connected to and moveable by the interior actuator, the driver member being alternately connectable such that the driver member is connectable to the first shaft to rotate the first shaft when the offset spacing between the first axis and the second axis is the first offset spacing, and connectable to the second shaft to rotate the second shaft when the offset spacing between the first axis and the second axis is the second, greater offset spacing.

2. The interconnected lock of claim 1, wherein the driver member is a linkage arm having a lower end connected to and moveable by the interior actuator, the linkage arm having a length extending upwards with first and second upper linkage arm portions, the first upper linkage arm portion having a first distance from the lower end for connecting to and rotating the first shaft, and the second upper linkage arm portion having a second distance from the lower end for connecting to and rotating the second shaft, the linkage arm being alternately connectable such that the first upper linkage arm portion is connectable to the first shaft to rotate the first shaft when the offset spacing is the first offset spacing, and the second upper linkage arm portion is connectable to the second shaft to rotate the second shaft when the offset spacing is the second, greater offset spacing, to thereby actuate the deadbolt lock mechanism.

3. The interconnected lock of claim 2, further including a rotatable lower cam operable by the interior actuator, the lower cam having a pair of arms extending outward on opposite sides thereof.

4. The interconnected lock of claim 3 further including a sliding mechanism that is configured to be urged upward by one of the arms of the lower cam when the interior actuator is rotated.

5. The interconnected lock of claim 4, wherein the linkage arm is configured to be urged upward by a lower slider portion of the sliding mechanism to rotate the first or second shafts for actuating the deadbolt mechanism.

6. The interconnected lock of claim 5, further including an upper slider portion of the sliding mechanism connected to the lower slider portion, the lower end of the linkage arm being connected to the upper slider portion and extending upward therefrom.

7. The interconnected lock of claim 6, wherein the lower end of the linkage arm is connected by a pin to the upper slider portion.

8. The interconnected lock of claim 5, wherein lower edges of the sliding mechanism configured to be contacted by the arms of the lower cam are angled so as to define a shallow V-shape such that the lower edges extend upward from a centerline to opposite side edges of the sliding mechanism at an acute angle greater than zero degrees.

9. The interconnected lock of claim 2, further including first and second upper cam plates, the first upper cam plate connected to the first shaft, and the second upper cam plate connected to the second shaft, and wherein the first and second upper linkage arm portions are alternately connectable to the first and second upper cam plates, respectively.

10. The interconnected lock of claim 9, wherein the first upper linkage arm portion is connectable to the first upper cam plate by at least one first pin, and the second upper linkage arm portion is connectable to the second upper cam plate by at least one second pin, such that when the deadbolt is at the first offset spacing, the first upper linkage arm portion is connected to the first upper cam plate by the at least one first pin and the second upper linkage arm portion of the linkage arm is unconnected to the second upper cam plate, and when the deadbolt is at the second, greater offset spacing, the second upper linkage arm portion is connected to the second upper cam plate by the at least one second pin and the first upper linkage arm portion of the linkage arm is unconnected to the first upper cam plate.

11. The interconnected lock of claim 10, wherein the pins are located on the cam plates or the upper linkage arm portions, and wherein the linkage arm is connectable to the first or second upper cam plates without adding or removing any components of the interconnected lock.

12. The interconnected lock of claim 10, further including a tab configured to engage the first shaft when the first shaft is not connected to the linkage arm to lock the first shaft against rotation, and configured to engage the second shaft when the second shaft is not connected to the linkage arm to lock the second shaft against rotation, and wherein the at least one first pin on the first upper cam plate is configured to be oriented so as to not interfere with movement of the linkage arm when the first shaft is not connected to the linkage arm, and wherein the at least one second pin on the second upper cam plate is configured to be oriented so as to not interfere with movement of the linkage arm when the second shaft is not connected to the linkage arm.

13. The interconnected lock of claim 2, wherein the linkage arm is configured to move the deadbolt along the second axis from the latched position to the unlatched position at the same time that the interior actuator is configured to move the latchbolt along the first axis from the latched position to the unlatched position upon operation of the interior actuator, the linkage arm being alternately connectable for adjusting the offset spacing between the first and second axes, such that the first upper linkage arm portion is connectable to the first shaft to rotate the first shaft when the offset spacing between the first axis and the second axis is the first offset spacing and the second upper linkage arm portion is connectable to the second shaft to rotate the second shaft when the offset spacing between the first axis and the second axis is the second, greater offset spacing, to change the offset spacing between the deadbolt and latchbolt between a first distance, corresponding to the first offset spacing, and a second, longer distance, corresponding to the second, greater offset spacing.

14. The interconnected lock of claim 2, wherein the first and second upper linkage arm portions are alternately connectable to rotate the first and second shafts, respectively, without adding or removing any components of the interconnected lock.

15. The interconnected lock of claim 2, wherein the first and second upper linkage arm portions are alternately connectable to rotate the first and second shafts, respectively, without use of tools.

16. The interconnected lock of claim 2, further including a tab configured to engage the first shaft when the first shaft is not connected to the linkage arm to lock the first shaft against rotation, and configured to engage the second shaft when the second shaft is not connected to the linkage arm to lock the second shaft against rotation.

17. The interconnected lock of claim 1, further including a cover over the driver member, the cover being removable to access the driver member to change connection of the driver member between the first shaft or the second shaft, the cover further having openings therein to support the first and second shafts.

18. A method of re-handing an interconnected lock for use on a door, the method comprising: providing the interconnected lock of claim 2, wherein the lock further includes first and second upper cam plates, the first upper cam plate connected to the first shaft, and the second upper cam plate connected to the second shaft, the first and second upper linkage arm portions being alternately connectable to the first and second upper cam plates, respectively; connecting the linkage arm to one side of the first and second upper cam plates for handing the lock for a right-hand operation; and connecting the linkage arm to an other side of the first and second upper cam plates for handing the lock for a left-hand operation.

19. The method of claim 18, wherein the first and second upper linkage arm portions are alternately connectable to the first and second upper cam plates, respectively, by pins located on the one side and the other side; and connecting the linkage arm to one of the pins on the one side of the first and second upper cam plates for handing the lock for a right-hand operation; and connecting the linkage arm to one of the pins on the other side of the first and second upper cam plates for handing the lock for a left-hand operation.

20. A method of adjusting offset spacing between a deadbolt and a latchbolt in an interconnected lock for use on a door, the method comprising: providing the interconnected lock of claim 2; operably connecting the linkage arm at the first upper linkage arm portion to the first shaft to rotate the first shaft and thereby actuate the deadbolt lock mechanism when the linkage arm is adjusted to a shorter offset spacing distance defined by the first offset spacing; and operably connecting the linkage arm at the second upper linkage arm portion position to the second shaft to rotate the second shaft and thereby actuate the deadbolt lock mechanism when the linkage arm is adjusted to a longer offset spacing distance defined by the second, greater offset spacing, whereby the first and second upper linkage arm portions are correspondingly connected to positions to the first and second shafts, respectively, without adding or removing any components of the interconnected lock.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The features of the invention believed to be novel and the elements characteristic of the invention are set forth with particularity in the appended claims. The figures are for illustration purposes only and are not drawn to scale. The invention itself, however, both as to organization and method of operation, may best be understood by reference to the detailed description which follows taken in conjunction with the accompanying drawings in which:

(2) FIG. 1 is an exploded perspective view of an embodiment of the interconnected lock of the present invention for mounting and use on the inside of a door.

(3) FIG. 2 is an exploded perspective view of an embodiment of the interconnected lock of the present invention for a mechanical lock assembly.

(4) FIG. 3 is an exploded perspective view of an embodiment of the interconnected lock of the present invention for an electromechanical lock assembly.

(5) FIG. 4 is a rear perspective, partially exploded view of an embodiment of the interconnected lock of the present invention showing the working components in connection with a deadbolt and a latchbolt.

(6) FIG. 5 is a rear perspective, partially exploded view of an embodiment of the interconnected lock of the present invention showing the set up for a latchbolt/deadbolt axis spacing, or offset distance, is at a smaller distance, for example, 4 in. (102 mm) center to center.

(7) FIG. 6 is a rear perspective, partially exploded view of an embodiment of the interconnected lock of the present invention showing the set up for a latchbolt/deadbolt axis spacing, or offset distance, is at a larger distance, for example, 5.5 in. (140 mm) center to center.

(8) FIG. 7 is a front perspective, partially exploded view of an embodiment of the front cover plate or escutcheon for enclosing the interconnected lock of the present invention showing the reversing thumbturn and deadbolt cover plate for different latchbolt/deadbolt axis spacings.

(9) FIG. 8 is a rear perspective view of the reversing thumbturn and deadbolt cover plate of FIG. 7.

(10) FIG. 9 is a front view of an embodiment of the escutcheon for enclosing an electromechanical lock assembly on the inside of the door in which the latchbolt/deadbolt axis spacing, or offset distance, is at a smaller distance, for example, 4 in. (102 mm) center to center.

(11) FIG. 10 is a rear perspective, partially exploded view of the escutcheon and electromechanical lock module of FIG. 9.

(12) FIG. 11 is a front view of an embodiment of the escutcheon for enclosing an electromechanical lock assembly on the inside of the door in which the latchbolt/deadbolt axis spacing, or offset distance, is at a larger distance, for example, 5.5 in. (140 mm) center to center.

(13) FIG. 12 is a rear perspective, partially exploded view of the escutcheon and electromechanical lock module of FIG. 11.

(14) FIG. 13 is a rear perspective, partially exploded view of the interconnected lock of the present invention showing the removable upper cover for easily changing handing of the lock mechanism.

(15) FIG. 14 is a rear perspective sectioned view of the lower portion of the interconnected lock of the present invention showing the guiding channels under the lower cover and the upper and lower sliders.

(16) FIG. 15 is a rear perspective view of the interconnected lock of the present invention set up for a 5.5 in. (140 mm) latchbolt/deadbolt axis spacing and a right-hand door installation.

(17) FIG. 16 is a rear perspective view of the interconnected lock of the present invention set up for a 5.5 in. (140 mm) latchbolt/deadbolt axis spacing and a left-hand door installation.

(18) FIG. 17 is a front perspective, partially exploded view of the thumbturn and deadbolt cover plate installation on the escutcheon of the interconnected lock of FIGS. 15 and 16.

(19) FIG. 18 is a rear perspective view of the interconnected lock of the present invention showing the lower, latchbolt cam plate and lower slider mechanisms.

(20) FIG. 19 is a rear perspective view of the interconnected lock of the present invention showing the upper, deadbolt cam plates and upper slider mechanisms.

DESCRIPTION OF THE EMBODIMENT(S)

(21) In describing the embodiment(s) of the present invention, reference will be made herein to FIGS. 1-19 of the drawings in which like numerals refer to like features of the invention.

(22) As shown by an embodiment in the drawings, the interconnected lock 20 of the present invention is mounted and for use on the inside of a door 21 (FIG. 1), where the lock has adjustable offset spacing between a deadbolt 50 and latchbolt 30 extending from door edge 21a. A front cover plate or escutcheon 22 encloses the lock assembly 20 over back plate 150 disposed on the inside surface of the door. The interconnected lock includes a latchbolt mechanism 32 mountable in a first bore 34 through the door 21. The latchbolt lock mechanism 32 includes a latchbolt 30 and a manually operated interior actuator or lever 36, here a handle extending laterally from and rotatable about latchbolt actuator driver or shaft 44, operable to move the latchbolt 30 between latched and unlatched positions along a first axis 42. The interconnected lock further includes a deadbolt lock mechanism 52 mountable in a second bore 54 through a door, where the second (deadbolt) bore 54 is spaced from the first (latchbolt) bore 34. The deadbolt lock mechanism 52 includes a deadbolt 50 moveable by the deadbolt lock mechanism 52 along the second axis 56 between latched and unlatched positions, with distance between the latchbolt first axis 42 and the deadbolt second axis 56 being the offset spacing 70. Deadbolt actuator or thumbturn 68 on deadbolt cover plate 29 is rotatable about deadbolt actuator driver or shaft 69 to cause deadbolt mechanism to latch and unlatch deadbolt 50 manually from the inside of the door. As part of the adjustment of lock assembly 20 to the different latchbolt-deadbolt offset distances, thumbturn 68 and shaft 69 are removed from the lock assembly, and deadbolt cover plate 29 may be rotated 180 degrees as shown by arrow 79 (FIG. 7) to align the deadbolt actuator shaft opening to the desired offset position of the deadbolt 50 and deadbolt mechanism 52 before mounting on escutcheon 22. Cover plate 29 then covers the opening 28a or 28b for deadbolt actuator shaft 69 which is not in use. A fixed tab 27 (FIGS. 5, 6, 8 and 17) on the inside of cover plate 29 engages the cam plate not in use through the escutcheon opening 28a or 28b, and locks the unused idle cam plate and associated shaft against rotation so that pins 114a, 114b (on cam plate 110) or pins 124a, 124b (on cam plate 120) are oriented in a position, e.g., vertically aligned, and do not interfere with movement of the driver member or linkage arm 90.

(23) The interconnected lock 20 also includes a rotatable lower cam plate connected to latchbolt actuator driver or shaft 44 and operable by the interior actuator, the lower cam having a pair of arms 46a, 46b (FIG. 4) extending outward on opposite sides thereof. Shaft 44 extends beyond cam plate 46 and engages an otherwise conventional latchbolt lock core (not shown) positioned in bore 34, such as a cylindrical or tubular lock, to move latchbolt 30 between its latched and unlatched positions upon rotation of the inner latchbolt actuator. When inner handle 36 is horizontal and latchbolt actuator shaft 44 is in its default position, latchbolt 30 is in its unretracted, latched position, and when inner handle 36 is rotated, latchbolt 30 moves inward to its retracted, unlatched position.

(24) Slider or sliding mechanism 80 forms part of the mechanism that translates rotation of the latchbolt actuator 36 to retract the deadbolt 50, and comprises lower and upper sliders 82, 84, respectively. Lower slider or sliding mechanism 82 is urged upward by one of the lower cam arms 46a or 46b when the interior actuator 36 is rotated. As shown in FIG. 18, the lower edges 82a, 82b of the lower slider contacted by the lower cam arms 46a, 46b, respectively, are angled from horizontal in the configuration of a shallow V so that the edge extends upward from the centerline to each opposite side edge of the lower slider at an acute angle greater than zero, with respect to horizontal. The rotational sliding contact of the lower cam arms 46a or 46b against the angled lower edges 82a, 82b, respectively, maximizes the linear travel distance of the lower slider, and increases the output driving torque of the deadbolt driver shaft which is ultimately rotated as described below. Springs 83a, 83b aligned on either side of a vertical center line are captured between slots 23a, 23b on the inside of the escutcheon 22 and the lower slider 82. Tabs extending inward from lower slider 82 engage and compress springs 83a, 83b as lower cam arms 46a or 46b move the lower slider upward, and the action of the springs urges the lower slider downward when force is removed from the actuator. Upper slider or sliding mechanism 84 is connected to the lower slider at an upper midpoint region. A driver member or linkage arm 90 is removably connected at a lower end 91 by a pin 86 on the upper slider and extends upward therefrom.

(25) The interconnected lock further includes a pair of upper cam plates, one upper cam plate 110 positioned at a first location, e.g., 4 in. (102 mm) from the latchbolt first axis, and the other upper cam plate 120 positioned at a second location, e.g., 5.5 in. (140 mm) from the latchbolt first axis. The first upper cam plate is disposed to be operably connected to the deadbolt lock mechanism 52 by driver or shaft 112 extending therefrom when it is at the first offset distance, e.g., 4 in. (102 mm) from the latchbolt first axis 42 (FIG. 5), and the second upper cam plate is disposed to be operably connected to the deadbolt lock mechanism 52 by driver or shaft 122 extending therefrom when it is at the second offset distance, e.g., 5.5 in. (140 mm) from the latchbolt first axis 42 (FIG. 6).

(26) Deadbolt lock mechanism 52 includes a deadbolt actuator shaft extending from an interior thumbturn 68 through an opening and locking into deadbolt cam plate 110 or 120, depending on the offset distance. Deadbolt bore 54 extends perpendicularly from the inner surface of door 21 to its outer surface (FIG. 1). Deadbolt lock drivers or shafts 112 and 122 extend beyond their respective cam plates 110 and 120 (FIGS. 4, 5 and 6) to engage an otherwise conventional security lock (not shown) in bore 54 operated by a key on the outside of the door or thumbturn on the inside of the door to move deadbolt 50 between its latched and unlatched positions upon rotation of the deadbolt actuator shaft.

(27) The linkage arm 90 has a length extending upwards from the upper slider 84 and two upper positions 92, 94 for alternate pin connection to the upper cam plates (FIGS. 5, 6 and 19). Linkage arm 90 is generally curved to be disposed on one side or another of vertically aligned upper cam plate shafts 112, 122, with upper positions 92, 94 extending toward a vertical center line of the escutcheon. First upper position 92 is midway along the linkage length and second upper position 94 is at the upper end of the linkage length. To move the deadbolt 50 along the second axis 56a from the latched to the unlatched position when it is at the first offset distance, e.g., 4 in. (102 mm) from the latchbolt first axis 42, an opening 93 in the first linkage upper position 92 may be removably connected to the first upper cam plate 110 by pin 114a or 114b (FIG. 5) at a location on the cam plate 110 a distance from the second axis 56a, to rotate the cam plate 110 as the upper slider 84 is urged upward by the lower slider 82 and lower cam arm 46a or 46b during rotation of the interior actuator or lever 36. When operating the deadbolt 50 at the first offset spacing, the second upper pin position 94 of the linkage 90 is unconnected to the second upper cam plate 120.

(28) To move the deadbolt 50 along the second axis 56b from the latched to the unlatched position when it is at the second offset distance, e.g., 5.5 in. (140 mm) from the latchbolt first axis 42, an opening 95 in the second linkage upper position 94 may be removably connected to the second upper cam plate 120 by a pin 124a or 124b (FIG. 6) at a location on the cam plate 120 a distance from the second axis 56b, to rotate the cam plate 120 as the upper slider 84 is urged upward by the lower slider 82 and lower cam arm 46a or 46b during rotation of the interior actuator or lever 36. When operating the deadbolt 50 at the second offset spacing, the first upper pin position 92 of the linkage 90 is unconnected to the first upper cam plate 110.

(29) Regardless of the offset spacing between the deadbolt and latchbolt, rotating the inner handle 36 moves the linkage arm 90 upwards, rotating the upper cam plate 110 or 120 operably connected to the deadbolt lock mechanism 52 and automatically retracts both the latchbolt 30 and the deadbolt 50, without having to separately unlock the two. At this point, the user may open the door. After the user is outside and the door is closed, the latchbolt 30 normally returns to the latched position automatically, and the deadbolt 50 may be manually latched by use of a key on an exterior deadbolt security lock 58 or whatever security locking mechanism is employed. It should be noted that operation of the handle 38 on the outer side of the door does not rotate latchbolt cam plate 46, and the deadbolt 50 may only be retracted from the outside of the door by the key or otherwise unlocking the deadbolt security locking mechanism.

(30) To provide for easy installation, the slider mechanism 80, linkage 90 and cam plates 110, 120 are mounted inside the front wall of escutcheon 22, and lower and upper cover plates 140 and 144, respectively are provided thereover. As shown by way of example in FIG. 13, lower cover plate 140 is substantially flat and is securely mounted inside the escutcheon, and is not intended to be removed for offset adjustment or re-handing. Side channels 141a, 141b shown in FIG. 14 are formed between the escutcheon and the edges of substantially flat lower cover plate 140 to guide the sliding of the edges of lower slider 82 upward and downward, and upward facing tabs 142a, 142b are provided at the opposite sides of the upper end to retain the edges 145a, 145b, respectively, of the arms extending laterally on upper cover plate 144. Upper cover plate 144 is intended to be removably secured by screw fasteners through openings 147a, 147b (FIG. 13) in the lateral arms, so that linkage arm 90 may be accessed and set as needed for offset adjustment or re-handing. Upper cover plate 144 includes central openings 146a, 146b which align with and serve as bearing journals to support rotation of upper cam plate shafts 112, 122, respectively. A vertically aligned slot 148 guides upward and downward movement of pin 86 holding upper slider 84.

(31) To re-hand or reverse the lock mechanism from right-handed operation to left-handed operation, and vice-versa, the symmetry of the upper slider 84 and upper cam plates 110 and 120 about a central vertical line enables the linkage arm 90 to be easily flipped from one side to the other, as shown by way of example in FIGS. 15 and 16. Using a wider 5.5 in. (140 mm) offset as an example, in a right hand configuration linkage arm lower end 91 is connected to upper slider pin 86, and linkage arm second upper position opening 95 is connected to second upper cam plate pin 124a. First upper cam plate 110 at the 4 in. (102 mm) offset is the idle cam, and is locked by tab 27 (FIG. 17) with the pins 114a, 114b vertically aligned on the side of shaft 112 opposite linkage arm 90, with linkage arm first upper position opening 93 unconnected. To change to the left hand configuration, linkage arm 90 is removed from pins 86 and 124a, and flipped around to the other side of shafts 112, 122, and linkage arm lower end 91 is again connected to upper slider pin 86. Linkage arm second upper position opening 95 is then connected to the opposite second upper cam plate pin 124b. The idle first upper cam plate 110 rotated 180 degrees and again locked by tab 27 with the pins 114a, 114b vertically aligned on the side of shaft 112 opposite linkage arm 90. If the 4 in. (102 mm) offset is desired, pins 114a (right hand) and 114b (left hand) are similarly connected to linkage arm first upper position opening 93. Upper cam plate 120 becomes the idle cam, and is oriented with pins 124a, 124b aligned vertically opposite the linkage arm, and linkage arm second upper position opening 95 unconnected. Escutcheon openings 28a, 28b are marked with indicia to indicate right or left hand installation. Other than removing upper cover 144, no tools are required for the re-handing.

(32) The interconnected lock of the present invention permits an electromechanical lock module 130 (FIGS. 3 and 9-12) to be mounted on the escutcheon 22 to engage through openings 28a or 28b the first or second upper cam plate in use for the desired offset to control the remote latching or unlatching of the deadbolt. FIGS. 9 and 10 show an example of the electromechanical lock module 130 engaging the lower opening 28a for the smaller latchbolt/deadbolt offset and FIGS. 11 and 12 show the electromechanical lock module engaging the upper opening 28b for the larger latchbolt/deadbolt offset.

(33) Accordingly, the present invention provides an interconnected lock that is able to switch between different latchbolt-deadbolt offset spacings without adding or removing any components thereof. The interconnected lock of the invention may be switched between different latchbolt-deadbolt offset spacings without the potential of losing parts during the spacing adjustment. Additionally, the interconnected lock of the present invention is able to accomplish the switch between different latchbolt-deadbolt spacings without the need for using any tools. The linkage arm adjustment design configuration is an ergonomic and intuitively adjustable solution for the installer and cost effective for the manufacturer. Since no disassembly is required, installation time is reduced.

(34) While the present invention has been particularly described, in conjunction with a specific preferred embodiment, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. It is therefore contemplated that the appended claims will embrace any such alternatives, modifications and variations as falling within the true scope and spirit of the present invention.