Abstract:
Locksets primarily intended for use in interior residential doors and that have a concealed fastener mechanism positioned on one side of the lockset, the mechanism including connecting a first handle connected to a second handle through a spindle with the concealed fastener mechanism comprising a generally cylindrical housing including a torsion spring, a timing plate and a cover plate, the housing including an internally threaded central aperture, the timing plate including at least one tab adapted to cooperate with said torsion spring to return the handle to its at-rest position after rotation, a spindle expansion and stabilizing screw adapted to eliminate any gap between the spindle and the timing plate and a spindle set screw that, when engaged eliminates any gap between the spindle and its handle to thereby eliminate the “wobble” that otherwise could be in the lockset.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application is a continuation-in-part of and claims the benefit of priority of U.S. application Ser. No. 13/940,178, filed Jul. 11. 2013, which claims the benefit of priority of U.S. provisional patent application 61/672,259, filed Jul. 16, 2012, both of which are incorporated by reference herein. 
     
    
     FIELD OF INVENTION 
       [0002]    The invention relates to the field of door locksets, including but not limited to interior doors such as interior passage and privacy locksets. 
       BACKGROUND 
       [0003]    Typical conventional door passage locksets include a handle or actuator that may be a knob or a lever. The locksets also include a spindle, a rosette on each side of the door and mounting screws that hold the lockset together and that are exposed on one of the rosettes. 
       SUMMARY 
       [0004]    The present concealed fastener locksets include embodiments of concealed fastener mechanisms that may be used with conventional knob and lever locksets that conceal the mounting screws on the rosette, that eliminate gaps or clearances between the lockset spindle and its timing plate and that eliminate gaps or clearances between the lockset spindle and the handles of the lockset. The present concealed lockset mechanisms provide for sleek, concealed fastener systems with no exposed screws and that can be used in brass, stainless steel, bronze, zinc, steel, aluminum, crystal and porcelain interior passage and privacy locksets. The present locksets include a concealed fastener cartridge adapted for use with a knob handle, and a cartridge adapted for use with a lever handle. Both types of locksets accommodate a privacy feature. Locksets of this type often exhibit what is known as a “wobble”, due to the existence of a small clearance between the spindle of the lockset and its timing plate, and between the spindle and the lockset&#39; s handle. Elimination of this wobble problem is provided in the present lockset, through use of an expandable spindle part and a set screw in combination with the expandable spindle part. 
         [0005]    Numerous features, aspects, and advantages of the present concealed fastener locksets will become better understood with regard to the following description, appended claims and accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]    The foregoing aspects and the attendant advantages of the present invention will become more readily appreciated by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein: 
           [0007]      FIG. 1  is a perspective, exploded view of a preferred knob handle embodiment of the present concealed fastener lockset assembly including a display block; 
           [0008]      FIG. 2  is a perspective, exploded view of the lockset assembly of  FIG. 1 ; 
           [0009]      FIG. 3  is a close up, perspective, exploded view of the concealed fastener mechanism of the  FIG. 1  embodiment; 
           [0010]      FIG. 4  is a close up, perspective, exploded view of a concealed fastener mechanism for an alternate concealed fastener lockset embodiment; 
           [0011]      FIG. 5A  is a perspective view of the concealed fastener lockset spindle assembly disassembled; 
           [0012]      FIG. 5B  is a perspective view of the  FIG. 5A  concealed fastener lockset spindle assembly assembled; 
           [0013]      FIG. 5C  is a cross-sectional view of the  FIG. 5A  concealed fastener lockset spindle assembly; 
           [0014]      FIG. 5D  is a view of the joining regions of the  FIG. 5A  concealed fastener lockset spindle assembly encircled in  FIG. 5C ; 
           [0015]      FIG. 6  is a perspective, exploded view of a preferred lever handle embodiment of the present concealed fastener lockset assembly; 
           [0016]      FIG. 7  is a cross-sectional view of an alternate embodiment spindle assembly; 
           [0017]      FIG. 8  is a transverse cross-sectional view of the  FIG. 7  embodiment spindle assembly taken along line A-A of  FIG. 7 ; 
           [0018]      FIG. 9  is a transverse cross-sectional view of the  FIG. 7  embodiment spindle assembly taken along line B-B of  FIG. 7 ; 
           [0019]      FIG. 10  is a perspective, exploded view of the  FIG. 7  embodiment spindle assembly used with a lever handle; 
           [0020]      FIG. 11  is a perspective view of the  FIG. 7  embodiment spindle assembly used with a lever handle, showing interior components in dashed lines; 
           [0021]      FIG. 12  is a perspective, cut away view of the  FIG. 7  embodiment spindle assembly used with a lever handle, showing interior components in the cut away area; 
           [0022]      FIG. 13  is a perspective, exploded view of the  FIG. 7  embodiment spindle assembly used with a knob handle; 
           [0023]      FIG. 14  is a perspective view of the  FIG. 7  embodiment spindle assembly used with a knob handle, showing interior components in dashed lines; and, 
           [0024]      FIG. 15  is a perspective, cut away view of the  FIG. 7  embodiment spindle assembly used with a knob handle, showing interior components in the cut away area. 
       
    
    
       [0025]    Reference symbols or names are used in the figures to indicate certain components, aspects or features shown therein. Reference symbols common to more than one figure are specific to the referenced figure and may or may not indicate like components, aspects or features shown in other figures. 
       DETAILED DESCRIPTION 
       [0026]    With reference to  FIG. 1  a complete assembly of a preferred embodiment  20  of the present concealed fastener locksets is shown. For convenience and ease of reference the lockset  20  is shown placed in a display block  22 , which in normal consumer use would be an entire, interior door. Latch  24  and face plate  26  are shown as adapted to be inserted into the display block  22  and retained in the block with conventional Phillips screws  28 . 
         [0027]    A preferred embodiment concealed fastener mechanism cartridge is shown at  30 . The cartridge  30  may also be referred to as a cassette  30 , but for convenience and consistency will be referred to as a cartridge. The cartridge  30  is positioned on one side of the door (the “concealed side” or a “first side”), which can be “inside” or “outside” relative to other structures of the home or other building in which the door is positioned. For example, in residential use the cartridge  30  could be placed on either side of the door. The  FIG. 1  embodiment lockset and its cartridge  30  are for use with a knob lockset. An alternate preferred embodiment lockset and cartridge are for use with a lever lockset. Rosette  32  is positioned on the side of the door that is opposite the concealed side of the door (the “second side”), and a corresponding rosette  34  is positioned on the concealed side of the door. Rosette fastener ring nut  36  is externally threaded and is adapted to be screwed into the cartridge  30 , causing the rosette  34  to abut against the door. As will be appreciated by those skilled in this field, the lockset embodiments described herein are particularly advantageous because they eliminate the need to manufacture one lockset for a “left-handed” door and a different lockset for a “right-handed” door. Rather the same lockset, as described herein, may be used for either a “right-handed” door or a “left-handed” door. 
         [0028]    Conventional shoulder washer  38  and knob  40  are shown on the second side of the door. Knob  42  is on the concealed or first side of the door and is adapted to be used with the concealed fastener mechanism  44 . Shim spacer  46  is in the knob assembly  48  on the second side. Timing plate  50  is also positioned on the second side of the door and it functions to hold down rotational return spring  52 . Conventional c-clip  54  holds the knob assembly  48  together. A preferred embodiment concealed fastener split spindle assembly is generally shown at  56  and with details shown in  FIGS. 5A-5D . 
         [0029]    Pairs of machine screws  58 , set screw sockets  60  and socket posts  62  function to hold the two knob assemblies together. Washer  64 , preferably made of a relatively hard, elastomeric material functions to reduce friction on knob  42  as it is rotated in either direction. Set screw  66  functions to retain knob  42  on the spindle  56  on the concealed side of the lockset, and corresponding set screw  72  retains knob  40  on the second side of the door. Preferably the set screws  66 ,  72  are for use with an Allen wrench. 
         [0030]    Conventional spindle clip  68  on the spindle  56  functions to set the distance that the spindle is inserted into the latch  24 . Cone spring  70  functions to bias the spindle  56  away from knob  40  and toward knob  42 . Set screw  72  is positioned in knob  40  and serves two functions. First set screw  72  prevents spindle  56  from escaping from knob  40 , while permitting limited reciprocation of the spindle  56 . Secondly, once spindle  56  has been inserted through the latch  24  mounted in the door and c-clip  54  abuts against latch  24 , then set screw  72  is tightened down to secure spindle  56  for proper operation of the lock. The thickness of the particular door determines when the c-clip  54  abuts against latch  24 . With a relatively thin door, relatively more of the spindle will be contained within the knob  40 , and with a relatively thick door relatively less of the spindle will be contained within the knob  40 . 
         [0031]    Tool  74  is adapted to rotate to tighten or loosen and remove rosette ring nut  36 . Tool  74  is preferably made of a metal or of a polymeric material that is of sufficient hardness and strength to enable tightening of the ring nut  36  by hand or by a wrench or pliers. Tool  74  may have two or more flat surfaces to enable operation with pliers or a wrench. As shown in  FIG. 1  rosette ring nut  36  has four rectangular-shaped female indentations, preferably located 90° apart from each other, and tool  74  has four corresponding, complementary male protrusions adapted for cooperation with the indentations on the ring nut  36 . Other complementary shapes and forms may be used. 
         [0032]    Referring to  FIG. 2 , an exploded view of an alternate embodiment  76  of the concealed fastener mechanism is shown, including the addition of a preferred post alignment device  78 , a privacy latch  80  and a strike plate  82 . The  FIG. 2  post alignment device  78  is preferably of a sturdy polymeric material. The device  78  functions to keep privacy rosette  84  from rotating during use, and is adapted to secure the latch  80  and to align the posts  86 ,  88  along the top and bottom grooves of the mechanism  78 . 
         [0033]    Again referring to  FIG. 2 , the privacy assembly includes privacy pin  90  which extends through a hole  92  in the rosette  94  and threads into the privacy latch  80  at the privacy latch trigger shown at  96 . The  FIG. 2  latch  80  is fastened to the door with wood screws  98 .  FIG. 2  also shows conventional strike plate  82  and wood screws  100 , preferably of the same type and size as the wood screws  98  used for the latch  80 . The  FIG. 2  latch  80  differs from the  FIG. 1  latch  24  in that the  FIG. 2  latch  80  includes the privacy assembly and preferably is a 28° rotation latch. The  FIGS. 1 and 2  latches  24 ,  80  may also provide for different degrees of rotation required to latch and unlatch the lockset. Preferably the  FIG. 2  latch  80  is configured to latch and unlatch with a 28° rotation. Conventional latches also typically are made to operate with a rotation in the range of 45°-60°, for example a 50° rotation. The privacy pin  90  operates simply by pushing to lock the door. As the door handle (knob or lever) is rotated from the same side, the privacy mechanism operates to unlock the latch so that there is no need to withdraw the pin  90 . Allen wrench  102  is shown in  FIG. 2 , and may be used to tighten or loosen the set screws in the handles of the locksets. Tool  74  is also shown in  FIG. 2  and is described with respect to  FIG. 1 . 
         [0034]    Referring to  FIG. 3  an exploded view of a preferred cartridge spring assembly  104  for use with a knob is shown. Concealed fastener spring housing  106  houses knob timing plate  108  and knob spring  110 . The spring  110  and plate  108  are held in place by cover plate  112  having three holes  114  and three machine screws  116 . The housing  106  includes internal threads  118  to accommodate the external threads of the rosette ring nut  36 . 
         [0035]    The knob timing plate  108  functions to keep the spindle  56  aligned with latches  24  and  80 . The distal end of spring  110  extends at a right angle from the periphery of the spring  110  and functions as a stop to rest against shoulder  120  in the housing  106 . 
         [0036]    With reference to  FIG. 4 , a preferred cartridge spring assembly  122  for use with a lever is shown. Concealed fastener spring housing  124  houses lever timing plate  126  and lever return spring  128 . Spring housing  124  for the lever embodiment is preferably of the same construction as the spring housing  106  for the knob embodiment shown in  FIG. 3 . Again referring to  FIG. 4 , the timing plate  126  and spring  128  are held in place by housing cover plate  112 , having three holes  114  and three machine screws  116 . The lever spring housing  124  includes internal threads  130  to accommodate the external threads of the rosette ring nut  36  of  FIGS. 1 and 2 . The timing plate  126  for the lever embodiment is of a different construction than the timing plate  108  for the knob embodiment. The  FIG. 4  lever timing plate  126  preferably has a single tooth or projection  132 . In one preferred embodiment the tooth  132  is adapted for only a 28° rotation for latching/unlatching. Conventional coil spring  128  has a distal end  134  which extends 90° from the outer coil of the spring  128  and abuts either side of shoulder  136  in the housing  124 . 
         [0037]    Referring to  FIGS. 5A , B, C and D, a preferred concealed fastener spindle assembly  138  is shown.  FIG. 5A  shows the disassembled split spindle male member  140  and female member  142  preferably having four rectangular tabs, one of which is shown at  144 . Each of the tabs  144  has three sides cut-out and one side attached to the s top surface of the female member  142 . Preferably, such tabs  144  are included on the top, bottom and both sides of the female member  142 .  FIG. 5B  is a cross-sectional view of the assembled spindle assembly  138 , showing two of the four tabs crimped inward toward the center, and  FIG. 5C  is a close-up, showing the crimped tabs  144  in greater detail. The crimped tabs  144  function to permit rotation of the two spindle members  140 ,  142  relative to each other, and to prevent the two members from separating from each other during normal use.  FIG. 5D  shows the assembled split spindle  138 . The split spindle is preferably used for both the knob and lever embodiments of the concealed fastener locksets. 
         [0038]    Referring to  FIG. 6 , an exploded view of a preferred lever handle embodiment  150  of the present concealed fastener lockset assembly shows major components lever  152 , lever  154  and cartridge  156 . A post alignment device  158 , rosettes  160  and  162  and latch  164  are also shown in  FIG. 6  and are as described above. 
         [0039]    Referring to  FIGS. 7-15  an alternate preferred concealed fastener spindle assembly  170  is shown.  FIG. 7  is shows the assembled split spindle male member  172  and female member  174  showing one of the four rectangular tabs, shown at  176  and described above. Channel  178  in female member  174  provides the channel for capturing spindle clip  68 , which in turn sets the distance the spindle is inserted into the latch. Male member  172  includes a central, threaded channel  180  and an interior spindle stabilizing screw  182 . As the stabilizing screw  182  is rotated into the channel  180 , the leading edge of the screw  182  forces a slight expansion of the outer walls of the member  172  radially outward. In the absence of stabilizing screw  180  there would be a clearance between the outer periphery of the male member  172  (at the cartridge side of the lockset) and the timing plate of the lockset. As will be described in detail, the leading edge of the screw  182  eliminates this clearance. The distal, or opposite end of the screw  182  is preferably adapted to receive an Allen wrench. 
         [0040]    With insertion of the stabilizing screw  182  into the longitudinal cavity of the male member  172 , the four sides of the male member of the spindle are expanded at the leading edge of the screw  183 , the clearance between the spindle and the timing plate is eliminated. To address any clearance between the spindle and the handle (knob or lever) the distal end of set screw  184  is provided and adapted to contact the male member of the spindle. Set screw  184 , also preferably adapted for an Allen wrench driver is shown in  FIGS. 7 and 9 . The  FIG. 7  embodiment split spindle is preferably used for both the knob and lever embodiments of the concealed fastener locksets. 
         [0041]      FIG. 8  is a cross-sectional view of the spindle male member  180  at line A-A and shows the channel inside of the male member at a location remote from the set screw  184 . At this location, the leading edge of expansion screw  182  is shown causing a slight expansion of the spindle. When screw  182  is threaded into the internal, threaded channel of the male member  172 ,  FIG. 8  shows the expansion at line A-A, and reduction of the overall potential wobble effect by eliminating clearance between the spindle and the timing plate  126 , or timing plate  108  for the lever handle or knob handle embodiments, respectively as shown in  FIGS. 3 and 4 . 
         [0042]      FIG. 9  is a cross-sectional view of the spindle male member  180  at line B-B, through the location of the centerline of set screw  184 . At this location and with set screw  184  rotated or threaded inward to “set” the spindle, screw  184  functions to eliminate any clearance between the male member of the spindle and the handle, and thus to eliminate any remaining wobble in the lockset. Threading the screw  184  inward and up against the male member  172  forces distortion of regions  186  and  188 . Rotation of the set screw  184  inward (downward in  FIG. 9 ) and against the male member  172  forces region  186  outward (to the left in  FIG. 9 ) and against stabilizing screw  182 , which is then forced downward and to the right in  FIG. 9 . The rotation of the screw  184  inward to contact against the walls of the male member  172  [stop] also forces region  188  outward (to the right in  FIG. 9 ) and against the stabilizing screw  182  as shown in  FIG. 9 . The insertion of the set screw  184  in this way expands the outer periphery of the male spindle member in the region adjacent the contact points of the screw  184  to the spindle and in turn the outer part of the spindle to the inner surface of the handle. By expanding this region of the spindle, any remaining clearance between the spindle and its handle is removed, thus removing the “wiggle” or “wobble” that otherwise would result from the existence of such clearance. 
         [0043]    Referring to  FIGS. 10-12 , spindle assemble  170  is shown in relation to lever handle  154  in a perspective, exploded view. These figures show the structural and functional relationships between the internal stabilizing screw  182 , spindle male member  172 , set screw  184 , timing plate  126  and its tooth  132  in relation to operating the lockset and, in particular, eliminating handle wobble. 
         [0044]    Referring to  FIG. 13-15 , spindle assemble  170  is shown in relation to knob handle  42  in a perspective, exploded view. These figures show the structural and functional relationships between the internal stabilizing screw  182 , spindle male member  172 , set screw  184 , timing plate  108  in relation to operating the lockset and, in particular, eliminating the relative motion between the spindle and the handle. 
         [0045]    Although specific embodiments of the invention have been described, various modifications, alterations, alternative constructions, and equivalents are also encompassed within the scope of the invention. 
         [0046]    The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. It will, however, be evident that additions, subtractions, deletions, and other modifications and changes may be made thereunto without departing from the broader spirit and scope of the invention as set forth in the claims.