Abstract:
A multi-point latch assembly having a single adjustment point for shifting the position of two or more latching members. The latch mechanism includes a housing and a carrier assembly received in the housing. The carrier assembly includes a pair of latch hooks. A carrier position adjustment assembly operably couples the housing and the carrier assembly such that the carrier assembly is selectively shiftable in the housing with the carrier position adjustment assembly to alter the distance the latch hooks protrude from the housing when the latch hooks are positioned in the second position. An anti-slam mechanism may also be coupled with the carrier, and may be selectively shiftable with the same adjustment mechanism.

Description:
RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 60/922,166, entitled TWO-POINT LOCK FOR SLIDING DOOR, filed Apr. 6, 2007, and also claims the benefit of U.S. Provisional Application No. 60/944,259, entitled MULTI-POINT LOCK MECHANISM, filed Jun. 15, 2007, said applications being hereby fully incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to adjustable lock mechanisms for sliding doors. More particularly, a two-point lock of the present disclosure provides for a single point of adjustment for varying the position of two locking members. 
     BACKGROUND OF THE INVENTION 
     In a typical sliding door installation, such as sliding patio doors, the door is latched by a mechanism mounted in the locked face of the stile of a sliding door. In a single-point latch mechanism, a single hook, or other latching component engages a receiving (keeper) component disposed in the door jamb to latch the door and maintain the door in a latched state. While single-point latch mechanisms often provide satisfactory performance, the use of a single hook often fails to provide the security desired by a homeowner. 
     In response to the desire for increased security by homeowners, multi-point latch mechanisms have been developed for use in sliding door installations. These multi-point mechanisms can be mounted in the locked face of the stile of the sliding door with multiple latching elements engaging a receiving structure mounted on door jambs. These multi-point latches increase the security of the latch mechanisms by providing additional locking strength, thereby diminishing the likelihood of forced entry. 
     A typical problem arising during installation of sliding door latches is that the latch elements may not securely engage with the keeper due to variations in construction. In these cases it is desirable to adjust the position of the latch elements, particularly the distance by which the latch elements project from the mechanism, or the keeper or both to attain secure engagement. Prior multi-point latch mechanisms, however, have sometimes included no adjustment mechanism at all for the latch elements, or have included complicated mechanisms requiring separate adjustments for each latching point. Further, while previous attempts have been made to provide a multi-point latch mechanism with a single adjustment point for simultaneously adjusting the position of more than one of the latch points, these attempts have resulted in mechanisms in which the adjustment mechanism shifts one latch point more than another. The result is still less than ideal latch engagement. 
     A further drawback of known adjustable multi-point latch mechanisms is that the range of adjustment of the mechanism is typically not visually evident. Hence, it cannot be readily determined whether the device is at or near one of the limits of travel without actually operating the adjustment until the limit is reached. 
     Thus, there still exists a need in the industry for a multi-point latch assembly that not only increases security, but which provides for quick and easy adjustment of the latches for proper engagement with the receiving structure. 
     SUMMARY OF THE INVENTION 
     Embodiments of the invention substantially meet the aforementioned need of the industry by providing a multi-point latch assembly having a single adjustment point for varying the position of one or more latching members. 
     In an embodiment of the invention, a sliding door assembly includes a door frame defining an opening, and a door slidably shiftable in a track on the door frame to open and close the opening defined by the door frame. The door includes a vertically oriented stile having a mortise in an edge thereof. A latch assembly is received in the mortise, the latch assembly including a housing and a carrier assembly received in the housing. The carrier assembly includes a pair of latch hooks with an actuator linkage operably coupled thereto. The latch hooks are selectively shiftable with the actuator linkage between a first position in which the latch hooks are substantially within the housing and a second position in which a portion of each of the latch hooks protrudes substantially the same distance from the housing to engage the door frame. The latch assembly further includes a carrier position adjustment assembly operably coupling the housing and the carrier assembly. The carrier assembly is selectively shiftable in the housing with the carrier position adjustment assembly to alter the distance the latch hooks protrude from the housing when the latch hooks are positioned in the second position. 
     In further embodiments, the carrier assembly may include an anti-slam mechanism. The anti-slam mechanism may include a button that protrudes from the housing, and the anti-slam mechanism may be shiftable with the carrier position adjustment assembly to alter a distance the button protrudes from the housing. 
     In further embodiments, the carrier position adjustment assembly may include a rotatable screw. The carrier position adjustment assembly may include a visual indicator for indicating the position of the carrier relative to the limits of travel of the carrier. The housing may define an elongate aperture for accessing the rotatable screw, and the position of the rotatable screw within the elongate aperture may comprise the visual indicator for indicating the position of the carrier relative to the limits of travel of the carrier. 
     In a further embodiment, a latch mechanism for a sliding door includes a housing and a carrier assembly received in the housing. The carrier assembly includes a pair of latch hooks with an actuator linkage operably coupled thereto, the latch hooks being selectively shiftable with the actuator linkage between a first position in which the latch hooks are substantially within the housing and a second position in which a portion of each of the latch hooks protrudes substantially the same distance from the housing. The latch mechanism further includes a carrier position adjustment assembly operably coupling the housing and the carrier assembly, the carrier assembly selectively shiftable in the housing with the carrier position adjustment assembly to alter the distance the latch hooks protrude from the housing when the latch hooks are positioned in the second position. 
     In further embodiments, a latch mechanism for a sliding door includes a housing and a carrier assembly received in the housing. The carrier assembly includes a pair of latch hooks with an actuator linkage operably coupled thereto, the latch hooks being selectively shiftable with the actuator linkage between a first position in which the latch hooks are substantially within the housing and a second position in which a portion of each of the latch hooks protrudes substantially the same distance from the housing. The latch mechanism further includes means for selectively shifting the carrier assembly in the housing to alter the distance the latch hooks protrude from the housing when the latch hooks are positioned in the second position. The means for selectively shifting the carrier assembly in the housing may include means for indicating the position of the carrier relative to the limits of travel of the carrier. 
     Hence, in embodiments of the invention, a multi-point latch assembly provides a single adjustment point for adjusting positions of two or more latching members. 
     Embodiments of the invention may include a method for adjusting the position of a pair of latching members using a single adjustment member. The method may further include providing a visual display of the position of the carrier relative to the limits of travel of the carrier, for example by displaying a position of the single adjustment member within a visible access channel. The method can further include resisting external forces placed on the latching members by providing opposed angled channels on a fixed outer housing and a movable inner housing so as to limit movement of the latching members to situations in which the single adjustment member is manipulated. 
     In embodiments of the invention, a multi-point latch assembly provides for operation of the latch with a single input member. 
     In embodiments of the invention, a multi-point latch assembly includes an anti-slam mechanism adjustable in position with a carrier position adjustment mechanism that also adjusts the position of two or more latching members. 
     Throughout the specification, any references to such relative terms as top and bottom, and the like, are intended for convenience of description and are not intended to limit the present invention or its components to any one positional or spatial orientation. It will be further understood that various dimensions of the components in the attached figures may vary depending upon specific applications and intended use of the invention without departing from the scope of the invention. 
     The above summary of various embodiments of the invention is not intended to describe each illustrated embodiment or every implementation of the invention. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the invention. The figures and the detailed description that follow more particularly exemplify these embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the following drawings, in which: 
         FIG. 1   a  is a fragmentary exploded perspective view of a sliding door with a multi-point latch assembly according to an embodiment of the present invention; 
         FIG. 1  is a side view of a multi-point latch assembly according to an embodiment of the invention; 
         FIG. 2  is a side view of the multi-point latch assembly of  FIG. 1  with a portion of the housing removed to expose the carrier assembly and with the latch hooks positioned in a retracted position; 
         FIG. 3  is a side view of the multi-point latch assembly of  FIG. 2  with the latch hooks positioned in an extended position; 
         FIG. 4  is a side view of the multi-point latch assembly of  FIG. 2  with a portion of the carrier assembly housing removed to expose the interior of the carrier assembly; 
         FIG. 5  is a side view of the multi-point latch assembly of  FIG. 4  with the carrier assembly shifted at its limit of travel in a direction toward the front side of the housing; 
         FIG. 6  is a side view of the multi-point latch assembly of  FIG. 4  with the carrier assembly shifted at its limit of travel in a direction away from the front side of the housing; 
         FIG. 7  is a side view of the multi-point latch assembly of  FIG. 4  depicting the mechanism at an intermediate position during operation of the latch hooks; 
         FIG. 8  is a side view of the multi-point latch assembly of  FIG. 4  depicting the mechanism at another intermediate position during operation of the latch hooks; 
         FIG. 9  is a side view of the multi-point latch assembly of  FIG. 4  depicting the mechanism at a position during operation of the latch hooks in which the latch hooks are fully retracted; 
         FIG. 10  is a side view of the multi-point latch assembly of  FIG. 4  with the actuator slide plate removed to expose underlying portions of the mechanism; 
         FIG. 11  is a front view of the multi-point latch assembly of  FIG. 1 ; 
         FIG. 12  is a rear view of the multi-point latch assembly of  FIG. 1 ; 
         FIG. 13  is a front view of the multi-point latch assembly of  FIG. 1  depicting the latch assembly with the carrier at one of the limits of travel; 
         FIG. 14  is a front view of the multi-point latch assembly of  FIG. 1  depicting the latch assembly with the carrier at the limit of travel opposite that depicted in  FIG. 13 ; 
         FIG. 15  is a side view of the multi-point latch assembly of  FIG. 1  with the carrier positioned in a position away from the front of the housing and the latch hooks in a fully retracted position; 
         FIG. 16  is a side view of the multi-point latch assembly of  FIG. 1  with the carrier positioned in a position away from the front of the housing and the latch hooks in an intermediate position; 
         FIG. 17  is a side view of the multi-point latch assembly of  FIG. 1  with the carrier positioned in a position away from the front of the housing and the latch hooks in a fully extended position; 
         FIG. 18  is an opposing side view of the multi-point latch assembly of  FIG. 1 ; and; 
         FIG. 19  is a perspective view of a handle set and latch assembly according to an embodiment of the invention. 
     
    
    
     While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     A sliding door assembly  20  with a latch assembly according to embodiments of the invention is depicted generally in  FIG. 1   a . Sliding door assembly  20  generally includes door  22 , frame  24 , handle assembly  26  and latch assembly  30 . Door  22  is generally slidable in the direction of the arrows in tracks (not depicted) attached to frame  24  as is well known in the art. As depicted, latch assembly  30  is received in a mortise  27  in a vertical stile  28  of door  22 . A thumb turn  29  or other control having a tang  29   a  actuates latch assembly  30  as further described hereinbelow. 
     Latch assembly  30  according to an embodiment of the invention is depicted generally in  FIGS. 1-18 . The various components of latch assembly  30  may be formed from suitably durable materials including, for example, metals such as carbon steel, stainless steel, aluminum, and combinations thereof, or other materials such as high strength polymers and the like. Latch assembly  30  generally includes housing  32  and carrier assembly  34 . Housing  32  generally includes housing body  36 , cover plate  38 , and front escutcheon plate  40 . Housing body  36  generally includes wall  42 , opposing side walls  44 ,  46 , and front wall  48 . Cover plate  38  defines guide slots  50 , actuator aperture  52 , and apertures  54  for receiving fasteners  56  to fasten cover plate  38  to housing body  36 . Front escutcheon plate  40  defines hook ports  58  and adjustment screw aperture  60 . Front escutcheon plate  40  is fastened to front wall  48  with fasteners  62 . 
     Carrier assembly  34  generally includes carrier housing  64 , hook bolts  66 ,  68 , actuator slide plate  70 , actuator linkage  72 , carrier position adjustment assembly  74 , and anti-slam assembly  76 . Carrier housing  64  generally includes a pair of carrier housing halves  78 ,  80 . Carrier housing half  78  generally includes planar portion  82  with a projecting flange  84 . Carrier housing half  80  generally includes wall  86 , rear wall  88 , opposing side walls  90 ,  92 , and front wall  94 . 
     Each hook bolt  66 ,  68 , generally includes hook portion  96  and body portion  97 . Actuator pin  98  projects from body portion  97  of each hook bolt  66 ,  68 . As depicted in  FIG. 10 , hook bolts  66 ,  68 , are pivotally attached to wall  86  of carrier housing half  80  at pivots  100 ,  102 , respectively. 
     Actuator slide plate  70  defines two generally L-shaped hook actuator slots  104 ,  106 , and anti-slam notch  108 . Actuator linkage  72  generally includes cylinder  110 , link  112 , and spring  114 . Cylinder  110  includes projecting link arm  116  having coupling pin  118 . Spring  114  extends between lobe  120  of cylinder  110  and fastener boss  122  which extends from wall  42  of housing body  36 . Link arm  116  is pivotally coupled to link  112  at pivot  124 , and link  112  is pivotally coupled to actuator slide plate  70  at pivot  126 . Cylinder  110  defines key hole  128  for receiving actuator tang  29   a.    
     Means for selectively shifting the carrier in the form of carrier position adjustment assembly  74  generally includes post  130  and screw  132 . Post  130  is fixed to retainer plate  133  on the exterior of wall  42  of housing body  36  as further disclosed hereinafter. Screw  132  threads through an aperture in post  130 . 
     Anti slam assembly  76  generally includes block portion  134 , button  136  and spring  138 . Block portion  134  has projecting tab  140 . Spring  138  extends between block portion  134  and rear wall  88  of carrier housing half  80  and biases block portion  134  so that button  136  protrudes from front escutcheon plate  40 . 
     Hook bolts  66 ,  68 , are selectively positionable between an extended position as depicted in  FIG. 4 , in which the hook portions  96  project from hook ports  58  to engage a keeper in a door frame, and a retracted portion as depicted in  FIG. 9 , by rotation of cylinder  110 . A sequence of operation is depicted in FIGS.  4  and  7 - 9 . Initially, actuator slide plate  70  at its rightward limit of travel as depicted in  FIG. 4 . Spring  114  biases cylinder  110  in a clockwise direction and tongue  142  of actuator slide plate  70  rides over projecting tab  140  of block portion  134  of anti slam assembly  76 . As cylinder  110  is rotated counter-clockwise against the bias of spring  114 , link arm  116  and link  112  urge actuator slide plate  70  leftward. Actuator pins  98  slide in hook actuator slots  104 ,  106 , causing hook bolts  66 ,  68 , to rotate about pivots  100 ,  102 , respectively. Once actuator slide plate  70  nears its leftward limit of travel as depicted in  FIG. 9 , hook bolts  66 ,  68 , are fully retracted within housing  32 . Projecting tab  140  of block portion  134  of anti slam assembly  76  drops into anti-slam notch  108  of actuator slide plate  70  to prevent rightward movement of actuator slide plate  70  unless button  136  is pressed against the bias of spring  138  inward into housing  32 . In this position, spring  138  biases cylinder  110  in a counter-clockwise direction. To extend hook portions  96 , button  136  can be depressed into housing  32  to disengage projecting tab  140  from anti-slam notch  108 , and cylinder  110  can be rotated clockwise. 
     According to embodiments of the invention, carrier assembly  34  is selectively shiftable within housing  32  to enable adjustment of the distance hook portions  96  project outwardly from front escutcheon plate  40  when fully extended. Posts  144  and post  130  have a larger diameter central portion  145 , and a smaller diameter portion  145   a  at both ends. Smaller diameter portion  145   a  of posts  144  and post  130  are fixed to retainer plate  133  which is on the exterior of wall  42  of housing body  36  as depicted in  FIG. 18 . 
     As depicted in  FIG. 2 , guide slots  50  in cover plate  38  are oriented at an angle relative to front escutcheon plate  40 . Carrier housing half  78  defines guide slots  146  which are oriented in a direction generally transverse to the direction of orientation of guide slots  50 . Wall  42  of housing body  36  defines guide slots (not depicted) registered with guide slots  50  and oriented in the same direction, while wall  86  of carrier housing half  80  defines guide slots (not depicted) registered with guide slots  146  and oriented in the same direction. Smaller diameter portions  145   a  at the ends of posts  144  and post  130  extend through guide slots  50 ,  146 , and through the corresponding guide slots in wall  42  and wall  86  such that posts  130 ,  144 , are slidable therein. Larger diameter portion  145  of posts  130 ,  144 , is larger than the width of the guide slots in wall  42  and wall  86  so that wall  42  and wall  86  are captured between the larger diameter portions  145  of posts  130 ,  144 , and retainer plate  133  at the edges of the slots with retainer plate  133  being slidable on the outer surface of wall  42 . 
     Carrier housing half  78  is retained on carrier housing half  80  with fasteners  148  that thread through apertures  149  and into bosses  150  extending from carrier housing half  80 . Carrier housing half  78  may define arcuate guide slots  152 ,  154 , to receive and guide actuator pins  98  of hook bolt  66 ,  68 , respectively. Further, carrier housing half  78  defines guide slot  156  for guiding projecting tab  140  of anti slam assembly  76 . Cover plate  38  is retained on housing body  36  with fasteners  56  threaded into fastener boss  122  and fastener boss  158  which extend from wall  42  of housing body  36 . Fastener bosses  122 ,  158  pass though oblong apertures  160 ,  162 , in carrier housing half  78  and correspondingly registered oblong apertures in wall  86  to enable carrier assembly  34  to shift within housing  32 . 
     In use, the distance “X” by which hook portions  96  extend outwardly from front escutcheon plate  40  can be adjusted at any position between the maximally extended position depicted in  FIG. 3 , and the maximally retracted position depicted in  FIG. 17  with operation of screw  132  of carrier position adjustment assembly  74 . With the carrier assembly  34  in the position of  FIG. 3 , screw  132  is rotated counter-clockwise. Screw  132  threads out of post  130 , urging post  130  away from front escutcheon plate  40 . Posts  130  and  144  slide in the guide slots  50  and  146 . Opposing side walls  90 ,  92 , of carrier assembly  34  abut opposing side walls  44 ,  46 , of housing  34 , constraining the movement of carrier assembly  34  only in a direction perpendicular with front escutcheon plate  40 . Since retainer plate  133  is slidable on the outer surface of wall  42 , however, retainer plate  133  and posts  130 ,  144 , can also shift in a direction generally parallel to front escutcheon plate  40 . As a result, in a novel aspect of embodiments of the invention depicted in  FIGS. 13 and 14 , screw  132  shifts along adjustment screw aperture  60  as screw  132  is turned, thereby providing a visual means for indication of the position of carrier assembly  34  relative to its limits of travel. 
     In a further novel aspect of embodiments of the invention, anti slam assembly  76  is fully contained in carrier assembly  34 . As a result, the distance “Y” by which button  136  protrudes from front escutcheon plate  40  is simultaneously adjustable with screw  132  by the same degree as distance “X” of hook portions  96 . 
     In a further novel feature of embodiments of the invention, handle fastener holes  180 ,  182 , can accommodate door handle set mounting in more than one location relative to latch assembly  30  while retaining cylinder  110  in the same location. Hence, for example, the same latch assembly  30  may be utilized in either the right vertical stile of a sliding door that slides to the right to close, or in the left vertical stile of a sliding door that slides to the left to close, without requiring a different handle set. In addition, different handle sets having different fastener locations relative to the actuator tang location can be used with the same latch assembly  30  having only a single actuator cylinder  110 . 
     As depicted in  FIG. 19 , handle set  184  generally includes handle escutcheon  186  and handle  188 . Control lever  190  is operably coupled drive to actuator tang  29   a , which engages in cylinder  110 . Fasteners  192 ,  194 , secure handle set  184  to the sliding door. In  FIG. 19 , handle set  184  is oriented in a first position relative to latch assembly  30  in which tang  29   a  is engaged with cylinder  110  and fastener  192  passes through fastener hole  182 . This orientation of handle set  184  relative to latch assembly  30  might be used, for example, where latch assembly  30  is disposed in the right vertical stile of a door that slides to the right to close. Where handle set  184  is to be used in the left vertical stile of a door that slides to the left to close, however, latch assembly  30  may be simply inverted about its longitudinal axis so that fastener  19  passes through fastener hole  182  from the opposite side. It will also be appreciated that fastener  192  might be spaced a greater distance from tang  29   a  so as to pass through fastener hole  180 . In addition, latch assembly  30  might be inverted about a transverse axis so that tang  29   a  is engaged with cylinder  110 , but with fastener  194  passing through fastener hole  180  or fastener hole  182 . In this way, the same latch assembly  30  can accommodate a wide variety of handle sets oriented in a variety of positions and disposed in either vertical stile of the sliding door. 
     The embodiments above are intended to be illustrative and not limiting. Additional embodiments are encompassed within the scope of the claims. Although the present invention has been described with reference to particular embodiments, those skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. For purposes of interpreting the claims for the present invention, it is expressly intended that the provisions of Section 112, sixth paragraph of 35 U.S.C. are not to be invoked unless the specific terms “means for” or “step for” are recited in a claim.