Abstract:
A locking mechanism for a door includes an outside actuator, an inside actuator, and a housing removably fixed to the door. A locking bar is selectively engageable with the housing. A first cam member is operable to move the locking bar from an unlocked position wherein the locking bar is released from the housing and a locked position wherein the locking bar is fixedly coupled to the housing. A spindle is rotatably coupled to the inside actuator and selectively coupled to the outside actuator. A second cam member is coupled to the first cam member and to the spindle and operable to move the locking bar from the locked position to the unlocked position in response to rotation of the inside actuator from a neutral position to one of a first clockwise position and a second counterclockwise position.

Description:
BACKGROUND 
     The present invention relates to a device and method for achieving egress release of a locking mechanism at approximately the same angle of operation regardless of rotational direction. 
     Many locksets remain locked upon egress such that a user must unlock the door upon exiting a room or structure if he intends to return without using a key. 
     SUMMARY 
     In one embodiment of a locking mechanism for a door, the locking mechanism includes an outside actuator, an inside actuator, and a housing removably fixed to the door. A locking bar is selectively engageable with the housing. A first cam member is operable to move the locking bar from an unlocked position wherein the locking bar is released from the housing and a locked position wherein the locking bar is fixedly coupled to the housing. A spindle is rotatably coupled to the inside actuator and selectively coupled to the outside actuator. A second cam member is coupled to the first cam member and to the spindle and operable to move the locking bar from the locked position to the unlocked position in response to rotation of the inside actuator from a neutral position to one of a first clockwise position and a second counterclockwise position. 
     In another embodiment of a locking mechanism for a door having an inside actuator, the locking mechanism includes a housing and a locking bar selectively moveable between a locked position wherein the locking bar is fixedly coupled to the housing and an unlocked position wherein the locking bar is released from the housing. A turn button is disposed in the inside actuator and a plunger bar coupled to the turn button. A first cam member is coupled to the plunger bar and includes a sloped surface that translates the locking bar from the unlocked position to the locked position in response to movement of the turn button. A second cam member is selectively engageable with the first cam member. The second cam member is further coupled to the inside actuator. The locking bar is movable from the locked position to the unlocked position in response to movement of the turn button and in response to rotation of the inside actuator from a neutral position to one of a first clockwise position and a second counterclockwise position. 
     In another embodiment of a locking mechanism for a door, the locking mechanism includes an actuator and a housing removably fixed to the door. A locking bar is selectively moveable between a locked position wherein the locking bar is fixedly coupled to the housing and an unlocked position wherein the locking bar is released from the housing. A rotatable member is operable to move the locking bar from the locked position to the unlocked position in response to rotation of the actuator from a neutral position to one of a first clockwise position and a second counterclockwise position. 
     Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a lockset assembled in a door. 
         FIG. 2   a  is a partially sectioned perspective view of a lock mechanism with integral egress release. 
         FIG. 2   b  is an exploded view of the locking mechanism illustrated in  FIG. 2   a.    
         FIG. 3   a  is another partially sectioned perspective view of the lock mechanism of  FIG. 2   a.    
         FIG. 3   b  is an exploded view of the locking mechanism illustrated in  FIG. 3   a.    
         FIG. 4  is a perspective view of the housing of the locking mechanism of  FIG. 2   a.    
         FIG. 5  is a perspective view of a latch spindle of the locking mechanism of  FIG. 2   a.    
         FIG. 6  is a perspective view of a first cam member of the locking mechanism of  FIG. 2   a.    
         FIG. 7  is a perspective view of a second cam member of the locking mechanism of  FIG. 2   a.    
         FIG. 8   a  is a side view of the locking mechanism in the unlocked position. 
         FIG. 8   b  is a side view of the locking mechanism during a locking operation by the plunger bar. 
         FIG. 8   c  is a side view of the locking mechanism in the locked position. 
         FIG. 9   a  is a side view of the locking mechanism during an unlocking operation by the plunger bar. 
         FIG. 9   b  is a side view of the locking mechanism in the unlocked position. 
         FIG. 10   a  is a side view of the locking mechanism in the locked position prior to unlocking by clockwise egress release. 
         FIGS. 10   b - 10   d  are side views of the locking mechanism during the sequence of an unlocking operation by clockwise egress release. 
         FIG. 11   a  is a side view of the locking mechanism in the locked position prior to unlocking by counterclockwise egress release. 
         FIGS. 11   b - 11   i  are side views of the locking mechanism during the sequence of an unlocking operation by counterclockwise egress release. 
         FIG. 12  is a perspective view of the lockset of  FIG. 1  assembled in the door and shown from the opposite side of the door as  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION 
     Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. And as used herein and in the appended claims, the terms “upper”, “lower”, “top”, “bottom”, “front”, “back”, and other directional terms are not intended to require any particular orientation, but are instead used for purposes of description only. 
       FIG. 1  illustrates the external portions of a lock assembly  10  mounted within a door  20 . As illustrated, the lock assembly  10  includes a lever  24  housing a key cylinder  28  with an escutcheon  32  to conceal the interface of internal components of the lock assembly  10  with the door  20 . A latch  36  extends through a faceplate  40  mounted in the swing side end of the door  20  adjacent an opposing door frame (not shown). 
       FIGS. 2   a - 3   b  illustrate the locking mechanism  100  referenced with respect to a proximal end  104  and a distal end  108 . The locking mechanism  100  includes a housing  110  having a proximal face  114  adjacent an outside actuator or handle (e.g., a knob or lever, not shown) and a distal face  118 . The housing  110  defines an aperture  122  having a central axis  124  therethrough that receives an outside spindle  126 . The outside spindle  126  rotates from a first position to a second position in response to actuation of the outside handle to extend and retract the door latch and receives a lock cylinder (not shown) into a proximal end thereof in a manner known to those of skill in the art. Two elongated arcuate members  130 ,  134  extend from the distal face  118  of the housing  110  and are together shaped to contain and support the remaining components of the lock mechanism  100 . 
     With continued reference to  FIGS. 2   a - 3   b , a locking bar  144  is disposed perpendicularly to the central axis  124  and includes a centrally formed semicircular body  148  designed to offset the locking bar  144  from the central axis  124 . The locking bar  144  translates through its entire range of travel in the axial direction within a pair of diametrically opposed channels  154  formed in the outside spindle  126 . The ends  160  of the locking bar  144  cooperate with a pair of opposing slots  140  of the housing  110  (see  FIG. 4 ). When the locking bar  144  is positioned as illustrated in  FIGS. 2   a  and  3   a , i.e., adjacent to the distal face  118  of the housing  110 , the locking mechanism  100  is in a “locked” position, which impedes rotational movement of the locking bar  144 , and thus the outside spindle  126 , as will be further detailed. A plunger bar  164  operates about the central axis  124  and engages both the lock cylinder (not shown) received in the outside spindle  126  and a turn button  165  located within an inside actuator or handle  166 . The plunger bar  164  is shaped in the form of a cross with arms  168  defining shoulders  172 . The shoulders abut a first washer  180  adjacent a first end of a biasing member or spring  184 , the other end of which interacts with a second washer  188  to convey the force of the spring  184  to the locking bar  144  during operation. In the present construction, the biasing spring  184  is illustrated as a linear compression spring. A plunger washer  196  provides a stop for the plunger bar  164  and rests against features in the outside spindle  126 . 
     An inside latch spindle  200  operates the door latch and is driven by the inside handle (not shown) when the locking mechanism  100  is locked and by both the inside and outside handles when the locking mechanism  100  is unlocked. Referring also to  FIG. 5 , the latch spindle  200  includes a tubular body  204  sized to receive the plunger bar  164 . An arcuate head  208  includes an edge  212  and diametrically opposed slots  216  sized to engage and cooperate with the locking bar  144  when the locking mechanism  100  is unlocked. A pair of side lances  220  extend from the inside surface  224  of the arcuate head  208 . A pair of bottom lances  228  formed in the bottom surface  232  of the latch spindle protrude axially therefrom. 
     With continued reference to  FIGS. 2   a - 3   b  and to  FIG. 6 , a first cam member  240  includes a base  244  and arcuate opposing walls  248 . Bottom notches  252  disposed in the base  244  cooperate with the bottom lances  228  formed in the latch spindle  200  during operation, allowing the co-rotation between the latch spindle  200  and the first cam member  240 . Each of the walls  248  includes a first and second margin  256 ,  260  and a declination  264 . A top ledge  268  supports a portion of the locking bar  144  when locked and a depression  272  provides a stopping point for the locking bar  144  when unlocked. A bevel  276  is situated between the depression  272  and a protuberance  280  adjacent the top ledge  268 . 
     Referring to  FIGS. 2   a - 3   b  and  FIG. 7 , a second cam member  290  actuated by the plunger bar  164  includes opposing sloped surfaces  294  that interact with the locking bar  144  during locking and unlocking. Angled notches  298 , each having a side  302 , operatively couple with the first cam  240  during operation, as will be further described. 
     Referring again to  FIGS. 2   a - 3   b , a spring cage  310 , aided by hooks  314 , retains the locking mechanism components previously identified into the outer spindle  126 . 
     Referring to  FIG. 8   a , the locking mechanism  100  is in an unlocked state or position with components as previously identified. The plunger bar  164  is operational with the key cylinder (within the outside spindle  126 ) or a turn button  165  (within the inside handle  166 ). When either is rotated to “lock” the door, the plunger bar  164  rotates the second cam  290 , as shown in  FIG. 8   b . In the illustrated embodiment, the plunger bar  164  moves clockwise with respect to the distal end of the latch spindle  200  during locking. As the second cam  290  rotates clockwise, it turns the sloped surfaces  294  into contact with the locking bar  144 , driving the locking bar  144  toward the housing  110  and into engagement with the opposing slots  140  adjacent the distal face (not shown). Concurrently, the locking bar  144  withdraws from the slots  216  in the latch spindle  200  and pushes against the biasing spring  184  through the washer  188  to compress it as the sides  302  of the partially angled notches  298  in the second cam  290  contact the first margins  256  of the walls  248  of the first cam  240 . Referring to  FIG. 8   c , this forces the first cam  240  against the bottom lance  228  of the latch spindle  200  and toward the locking bar  144 . Aided by the bevels  276 , the locking bar  144  lifts off of the sloped surfaces  294  and onto the top ledges  268 , which hold the locking bar  144  in place in the locked position against the biasing force of the spring  184 . The locking bar  144 , engaged with the slots  140  in the housing  110  and with the channels  154  in the outside spindle  126 , inhibits the outside handle from turning, thus locking the lock mechanism  100  from the outside. The inside handle  166  acting on the latch spindle  200  is free to turn to activate the latch and the egress release function of the locking mechanism  100 . 
     Referring to  FIG. 9   a , unlocking the lock mechanism  100  through the plunger bar  164  (which unlocks in a counterclockwise direction) via the key cylinder or the turn button  165  directly drives the second cam  290 . The partially angled notches  298  of the second cam  290  interact with the declinations  264  of the first cam  240  to rotate the first cam  240  in a counterclockwise manner until the notches  252  in the base  244  of the first cam  240  are aligned with the bottom lances  228  of the latch spindle  200 . During this movement, the top ledges  268  of the first cam  240  are rotated out of engagement with the locking bar  144  (over the protuberances  280 ), and the spring load of the spring  184  on the locking bar  144  forces the first cam  240  downward along the bevels  276  (which assist in reengaging the notches  252  with the bottom lances  228 ) and down the sloped surfaces  294  of the second cam  290  as the notches  252  mate with the bottom lances  228 . In this position, the locking bar  144  is disposed within the slots  216  of the latch spindle  200  and the depression  272  of the first cam  240 , as illustrated in  FIG. 9   b . With the locking mechanism  100  in the unlocked position, the outside spindle  126  is coupled to the latch spindle  200  through the locking bar  144 , and the outside handle can rotate the latch spindle  200 , which in turn operates the latch and turns the inside handle  166 . 
     Referring to  FIGS. 10   a - 10   c , during an unlocking operation of the lock mechanism  100  by clockwise rotation of the inside handle, the latch spindle  200  is rotated clockwise. The bottom lances  228  of the latch spindle  200  align with the notches  252  in the base  244  of the first cam  240 . The biasing force on the locking bar  144  due to the spring  184  acts through the top ledges  268  to force the notches  252  into engagement with the bottom lances  228 . At the same time, the locking bar  144  pushes against the slopes  294  of the second cam  290  to rotate the second cam  290  counterclockwise until the locking bar  144  is positioned against the edges  212  of the latch spindle  200 , as shown in  FIG. 10   c . The latch spindle  200  rotates from approximately 20 degrees to approximately 30 degrees, and more specifically rotates approximately 24 degrees from a neutral position to engage the notches  252  in the base  244 . If rotated further, the latch spindle  200  carries the first cam  240  with it while the locking bar  144  remains in contact with the edges  212 . 
     Referring to  FIG. 10   d , when the handle is released, an inside handle spring (not shown) returns the latch spindle  200  to a neutral position. As the latch spindle  200  rotates back to the neutral position carrying the first cam  240 , the locking bar  144  disengages from the top ledges  212  and pushes the sloped surfaces  294 , rotating the second cam  290  in a counterclockwise direction. The biasing spring  184  continues to push the second cam  290  through the locking bar  144  until the locking bar  144  is disposed within the slots  216  of the latch spindle  200  and the depressions  272  of the first cam  240  (see, e.g.,  FIG. 9   b ), at which point the locking mechanism  100  is unlocked. 
       FIG. 11   a  shows the locking mechanism  100  in the locked position, identically with that of  FIGS. 8   c  and  10   a . Referring to  FIGS. 11   a  and  11   b , during an unlocking operation of the lock mechanism  100  by counterclockwise rotation of the inside handle, the latch spindle  200  is rotated counterclockwise. The side lances  220  of the latch spindle  200  contact the second margins  260  of the first cam  240 , causing the first cam  240  to turn with the latch spindle  200 . With the second cam  290  engaged to the first cam  240  through the interaction of the angled notches  298  with the declinations  264 , the first and second cams  240 ,  290  rotate in tandem and disengage the locking bar  144  from the top edges  268  of the first cam  240 . The force from the biasing spring  184  moves the locking bar  144  onto the edges  212  of the latch spindle  200 , as shown in  FIG. 11   c . The latch spindle  200  rotates from approximately 20 degrees to approximately 30 degrees, and more specifically rotates approximately 24 degrees from a neutral position to disengage the locking bar  144  from the top edges  268 . If the latch spindle  200  is rotated further counterclockwise, the first cam  240  continues to carry the second cam  290  and the locking bar  144  remains in contact with the edges  212 . 
     Referring to  FIG. 11   d , when the handle is released, the inside handle spring (not shown) returns the latch spindle  200  to a neutral position. As the latch spindle  200  rotates back to the neutral position, the notches  252  in the base  244  of the first cam  240  align with the bottom lances  228  of the latch spindle  200 . Concurrently, the side lances  220  engage the first margins  256  of the first cam  240  and force the first cam  240  downward due to contact between the angled notches  298  and the declinations  264 , as shown in  FIGS. 11   e ,  11   f , and  11   g . The biasing spring  184  pushes the locking bar  144  against the slopes  294 , imparting a counterclockwise force on the second cam  290  to further force the first cam  240  against the side lances  220  of the latch spindle  200 , which in turn forces the notches  252  of the first cam  240  to engage the bottom lances  228 . Once the angled notches  298  are no longer engaged with the declinations  264 , the locking bar  144  rotates the second cam  290  (through contact with the slopes  294 , see  FIG. 11   h ) and fully engages the slots  216  in the latch spindle  200  and the depressions  272  of the first cam  240 , unlocking the mechanism  100  as illustrated in  FIG. 11   i.    
     A locking mechanism with egress release eliminates the need for the user to unlock the door during normal daily activity and allows entrance and exiting without concern for being locked out. Integrating the egress function with the locking mechanism also minimizes the number of parts required in the lockset. In addition, releasing the locking mechanism upon egress at approximately the same angle of operation of the inside handle, whether a knob or a lever, for both clockwise and counterclockwise rotation, assures that the locking mechanism will perform as expected for both a right-handed and a left-handed door installation. 
     Various features and advantages of the invention are set forth in the following claims.