Abstract:
A securing mechanism for a hinged sidelight panel. The securing mechanism includes a center latch bolt for latching the hinged sidelight panel and remote locking mechanisms for locking the hinged sidelight panel. A single lever handle is used to selectively retract the remote locking mechanisms and the latch bolt. At a first orientation of the handle, both the remote locking mechanisms and the latch bolt are engaged. At a second orientation of the handle, the latch bolt remains engaged, but the remote locking mechanisms retracted. At a third orientation, both the remote locking mechanisms and the latch bolt are disengaged. The orientation of the handle informs an observer whether the locks are engaged. In one embodiment, the full rotation is about 90°, enabling the use of longer lever handles without interference from door frames.

Description:
RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 61/649,170, entitled HARDWARE FOR A HINGED SIDELIGHT PANEL, filed May 18, 2012, said application hereby fully incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The disclosed invention relates generally to doors with sidelight panels. More specifically, the invention relates latching hardware for hinged sidelight panels. 
     BACKGROUND 
     Hinged or “operable” sidelight panels have been limited in availability because the available hardware has undesirable aspects. Hardware options range from casement operators mounted to the frame to cam type handles or thumb turns. The aesthetically “out of place” appearance of these systems have deterred door manufacturers from offering operable side lights, particularly for high end door systems. 
     Certain hinged patio doors are intended as entry doors and have many extra features such as a deadbolt and anti slam devices that are not needed on a side light application. Other hinged sidelight panels feature mechanisms driven by a thumb turn knob that travels through approximately 135° rotation to activate the remote locks and latch bolt. The obtuse angle of rotation required for activation prevents the use of a longer handle to drive the mechanism because the handle will interfere with the door frame when rotated from horizontal. 
     What is needed is a hinged sidelight panel having hardware that performs the latching and securing operation within a smaller angle of rotation and without unneeded features associated with entry doors. 
     SUMMARY OF THE INVENTION 
     In various embodiments of the invention, a sidelight securing mechanism is provided that uses one handle to operate a center latch bolt as well as upper and lower remote locking mechanisms. In one embodiment, the hinged sidelight panel can be held closed by the center latch bolt only. If additional security is desired, the remote locking mechanisms can be engaged as well. The maximum angle of rotation is limited to approximately 90°, so that a lever handle (as opposed to a knob) can be used as a visual indicator to show when only the center latch bolt is engaged, or if the remote locking mechanisms are also engaged. 
     When the side light panel is in the closed position and the lever handle is in a first angular orientation (in one embodiment, substantially horizontal), the center latch bolt is engaged and the remote lock mechanisms are engaged. To disengage the remote lock mechanisms, the lever handle is rotated downward to a second angular orientation (in one embodiment, approximately 70° down from horizontal), leaving only the center latch bolt engaged. To open the hinged sidelight, the lever handle is rotated downward to a third angular orientation (in one embodiment, approximately 90° downward from horizontal) to fully retract the center latch bolt. The hinged sidelight panel can then be swung open and the lever handle released. In one embodiment, upon release of the lever handle, the center latch bolt is extended lever handle returns to the second angular orientation. When the lever handle is in the second angular orientation, the remote lock mechanisms remain retracted. 
     With the lever handle in the second angular orientation, closure can be accomplished by simply pushing the sidelight panel into the closed position. The center latch bolt is tapered and spring loaded and will automatically retract when contacting the strike plate and then engage the strike plate once the hinged sidelight panel is fully closed. In one embodiment, the lever handle remains in the second angular orientation, providing a visual indication that only the center latch bolt is engaged. The door can then be reopened by rotating the lever handle downward to the third angular orientation to release the center latch bolt. 
     In one embodiment, to engage the remote locking mechanisms when the hinged sidelight panel is held closed only by the latch bolt (i.e., the lever handle is in the second angular orientation), the elongated handle is rotated upward to the first angular orientation. 
     In an embodiment, a hinged door system for closing an opening in a structure includes a frame defining a primary door opening and a sidelight opening adjacent the primary door opening, a first primary hinged panel operably disposed in the primary door opening, and a secondary hinged panel operably disposed in the sidelight opening. A multi-point latching system on the secondary hinged panel includes a center cassette having an operating mechanism and a selectively retractable latch bolt operable with the operating mechanism, at least one remote latch mechanism spaced apart from the center cassette, the at least one remote latch mechanism including a selectively operable latch bolt, a coupler linking the at least one remote latch mechanism with the operating mechanism of the center cassette, and a rotatable lever handle operably coupled with the operating mechanism of the center cassette. When the handle is positioned in a first position, the latch bolt of the center cassette and the latch bolt of the at least one remote latch mechanism are extended to latch the secondary hinged panel in place in the sidelight opening, when the handle is positioned in a second position, the latch bolt of the at least one remote latch mechanism is retracted, and when the handle is positioned in a third position, both the latch bolts of the center cassette and the at least one remote latch mechanism are retracted to enable the secondary panel to be opened. 
     In a further embodiment, the second position of the handle is a first angular distance from the first position, and the third position is a second angular distance from the first position, the second angular distance being greater than the first angular distance. The first angular distance may be about 70 degrees. The second angular distance may be about 90 degrees. 
     In an embodiment, the multi-point latching system comprises two remote latch mechanisms. 
     In an embodiment the center cassette and the two remote latching mechanisms are disposed along a side margin of the secondary hinged panel opposite the hinges. One of the remote latching mechanisms may be disposed vertically above the center cassette and the other of the remote latching mechanism may be disposed vertically below the center cassette. The latch bolt of the center cassette can be spring-loaded. 
     In a further embodiment, a multi-point latching system includes a center cassette having an operating mechanism and a selectively retractable latch bolt operable with the operating mechanism. At least one remote latch mechanism is spaced apart from the center cassette, the at least one remote latch mechanism including a selectively operable latch bolt. A coupler links the at least one remote latch mechanism with the operating mechanism of the center cassette. A rotatable lever handle is operably coupled with the operating mechanism of the center cassette such that when the handle is positioned in a first position, the latch bolt of the center cassette and the latch bolt of the at least one remote latch mechanism are extended to latch the secondary hinged panel in place in the sidelight opening, when the handle is positioned in a second position, the latch bolt of the at least one remote latch mechanism is retracted, and when the handle is positioned in a third position, both the latch bolts of the center cassette and the at least one remote latch mechanism are retracted to enable the secondary panel to be opened. 
     In an embodiment, the second position of the handle is a first angular distance from the first position, and the third position is a second angular distance from the first position, the second angular distance being greater than the first angular distance. The first angular distance may be about 70 degrees, and the second angular distance may be about 90 degrees. 
     In an embodiment, the multi-point latching system includes two remote latch mechanisms. The center cassette and the two remote latching mechanisms can be disposed along a side margin of the secondary hinged panel opposite the hinges. One of the remote latching mechanisms can be disposed vertically above the center cassette and the other of the remote latching mechanism can be disposed vertically below the center cassette. The latch bolt of the center cassette can be spring-loaded. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The embodiments of the present invention may be more completely understood in consideration of the following detailed description of various embodiments in connection with the accompanying drawings, in which: 
         FIG. 1  is an elevation view of a patio door assembly in an embodiment of the invention; 
         FIG. 2  is a perspective view of a sidelight securing mechanism in an embodiment of the invention; 
         FIG. 3  is a perspective view of an lever handle assembly in an embodiment of the invention; 
         FIG. 4  is an elevation view of the center cassette of  FIG. 2  in an embodiment of the invention; 
         FIGS. 5 and 6  are perspective views of the center cassette of  FIG. 4  in when the latch bolt and the remote locking mechanisms are fully engaged in an embodiment of the invention; 
         FIG. 7  is a perspective view of the center cassette of  FIG. 4  when the remote locking mechanisms are retracted and the latch bolt is engaged; 
         FIG. 8  is a perspective view of the center cassette of  FIG. 4  when the latch bolt and the remote locking mechanisms are disengaged in an embodiment of the invention; 
         FIGS. 9A through 9C  are elevation views of the elongated handle assembly of  FIG. 3  in various states of operation in an embodiment of the invention; 
         FIGS. 10 and 11  are plan views of a remote locking mechanism in an embodiment of the invention; and 
         FIG. 12  is a perspective view of the remote locking mechanism of  FIG. 10  in an embodiment of the invention. 
     
    
    
     While the present 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 present invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present invention. 
     DETAILED DESCRIPTION 
     Referring to  FIG. 1 , a patio door assembly  20  including a patio door  22  and hinged sidelight panels  24  are depicted in an embodiment of the invention. The patio door assembly  20  comprises a frame  26  to which the patio door  22  and hinged sidelight panels  24  are mounted via hinges  28 , and includes interior frame members  32 . Each hinged sidelight panel  24  is characterized as having a hinged edge  34  and a latching edge  36  and includes an lever handle assembly  38  mounted thereto for operation of a securing mechanism disposed within. A center strike plate  42  is positioned on each interior frame member  32  proximate the corresponding lever handle assembly  38  for engagement with the mechanism of the corresponding hinged sidelight panel  24 . Each lever handle assembly  38  includes an lever handle  44  that extends to one side of a rotation axis  46  and away from the corresponding center strike plate  42 . In one embodiment, remote strike plates  48  are located on each hinged sidelight panel  24  above and below the center strike  42  plate for supplemental engagement with the mechanism. 
     Referring to  FIG. 2 , a sidelight securing mechanism  60  is depicted in an embodiment of the invention. In one embodiment, the sidelight securing mechanism  60  includes an upper bar assembly  62  and a lower bar assembly  64  connected together and disposed in grooves and pockets along the latching edge  36  of the sidelight panel  24 . The upper bar assembly  62  comprises a remote locking mechanism  66  attached to a faceplate  68  and tie bar  72 . The lower bar assembly  64  comprises a center cassette  74  and a remote locking mechanism  76  connected by a faceplate  78  and a tie bar  82 . The center cassette  74  drives the tie bars  72  and  82  in the upper and lower bar assemblies  62  and  64 . The center cassette  74  also includes a center cassette housing  83  and retractable latch bolt  134 . 
     Referring to  FIGS. 3 and 4 , the lever handle assembly  38  and the center cassette  74  driven thereby are depicted in an embodiment of the invention. In one embodiment, the lever handle assembly  38  is mounted to the inside face of the hinged sidelight panel  24  and includes a square or polygonal shaft  86  that extends into the hinged sidelight panel  24  for driving the center cassette  74 . The square shaft  86  is concentric with the rotation axis  46  and engages a square or polygonal aperture  88  in the center cassette  74  for driving a rotating crank  92  of the center cassette  74 . The rotating crank  92  includes a lobe cam  93  having a leading face  95 . A crank flat detent spring  94  is coupled to the center cassette housing  83  and arranged to apply a friction force against the lobe cam  93  on the rotating crank  92 . 
     The rotating crank  92  is slidingly engaged with a link plate pin  102  that extends from a link plate  104 , the link plate pin  102  being captured for slidable operation within a first slot  106  that is formed on the center cassette housing  83 . The link plate  104  is pivotally attached to an operation bar  108  that is mounted within the center cassette housing  83  and adapted to slide vertically within the center cassette housing  83 . A detent spring  112  is anchored on one end to a bushing  114  that is fixed to and extends between opposing walls of the center cassette housing  83 . The other end of the detent spring  112  is anchored to a spring pin  116  that extends from the operation bar  108 , the spring pin  116  being captured for slidable operation within a second slot  118  formed on the center cassette housing  83 . 
     In one embodiment, a crank spring  120  is operatively coupled with and is coiled around the rotating crank  92 . The crank spring  120  is loosely coupled to the rotating crank  92 . A first leg  122  of the crank spring  120  is in contact and rides along with the link plate pin  102 . The crank spring  120  includes a leg  124  on the other end, the leg  124  extending radially outward in a direction away from the axis of rotation  46  and is adapted to rotate along with the rotating crank  92 . 
     The leading face  95  of the lobe cam  93  is adapted to engage an upper extremity  126  of a kick plate  128  upon rotation through a first angle of rotation θ1. The kick plate  128  includes a pivot  132  that is operatively coupled to the center cassette housing  83 . The kick plate  128  is further adapted to engage a latch bolt  134  that extends laterally through the center cassette housing  83 . A cone spring  136  is positioned to engage with the latch bolt  134  as the latch bolt  134  is retracted into the center cassette housing  83 . 
     Referring to  FIGS. 5 through 8 , operation of the central cassette  74  is described. In operation, the square or polygonal shaft  86  of the lever handle assembly  38  drives the rotating crank  92  when the lever handle  44  is rotated about the rotation axis  46 . The rotating crank  92  drives the link plate pin  102  along the first slot  106  in the center cassette housing  83 , and the link plate pin  102  drives the link plate  104  which in turn drives the operation bar  108 . When the operation bar  108  has moved approximately half way through its travel, the detent spring  112  exerts a force that pushes the operation bar  108  to a fully extended position of travel. The operation bar  108  drives the tie bars  72  and  82  that drive the remote upper and lower remote locking mechanisms  66  and  76  in an action that, as described below, retracts the remote locking mechanisms  66  and  76 . 
     The lobe cam  93  on the rotating crank  92  is situated with respect to the upper extremity  126  of the kick plate  128  so that when the link plate pin  102  has traveled to the full limit of the first slot  106  in the center cassette housing  83 , the leading face  95  of the lobe cam  93  has also traveled substantially through the first angle of rotation θ1 and is engaged or nearly engaged with the upper extremity  126 . At this point, the rotating crank  92  can rotate an additional angle of rotation θ2. The leading face  95  of the lobe cam  93  exerts a force on the upper extremity  126  of the kick plate  128  which acts to rotate the kick plate  128  about its pivot, which in turn retracts the latch bolt  134  into the center cassette housing  83 . Retraction of latch bolt  134  causes compression of the cone spring  136 , which exerts a bias force on the latch bolt  134 . When the lever handle  44  is released, the bias force exerted by the cone spring  136  causes the latch bolt  134  to extend outward into an engagement position. 
     The crank spring  120  rides freely with the rotating crank  92  through the first angle of rotation θ1. Upon entering the additional angle of rotation θ2, the first leg  122  of the crank spring  120  engages with the link plate pin  102  which is at the extreme point within the slot  106 . The second leg  124 , however, engages the leading face  95  of the lobe cam  93  and so continues travel with the leading face  95 , which puts the crank spring  120  in tension. Thus, upon release of the lever handle  44 , the rotating crank  92  and lever handle  44  are returned back though the additional angle of rotation θ2 to rest at the first angle of rotation θ1. 
     When the lever handle  44  is returned to the horizontal position, the rotating crank  92  rotates in the opposite direction, driving the link plate pin  102 , the link plate  104 , and the operation bar  108  in the opposite direction. This action drives the tie bars  72  and  82  for extension of the remote locking mechanisms  66  and  76 . As the operation bar  108  moves approximately half through its travel, the detent spring  112  passes though an over-center condition to apply a force to assist the rotating crank  92  in returning the operation bar  108 . The operation bar  108  in turn pulls on the link plate  104  and link plate pin  102 , trapping the link plate pin against the lower end of the first slot  106 . The link plate pin  102  then holds the rotating crank  92  in the return position. The rotating crank  92  holds the handle  44  in the horizontal position, assisted by the friction force exerted by the crank flat detent spring  94 . 
     Referring to  FIGS. 9A through 9C , the angular orientation of the lever handle  44  is depicted in an embodiment of the invention. In one embodiment, when the latch bolt  134  and remote locking mechanisms  66  and  76  are engaged, the lever handle  44  is oriented substantially horizontally ( FIG. 9A ). When the latch bolt  134  is engaged with the remote locking mechanisms  66  and  76  retracted, the lever handle  44  is oriented at the first angle of rotation θ1 ( FIG. 9B ). When the latch bolt  134  and remote locking mechanisms  66 ,  76  are all retracted, the lever handle  44  is oriented at an angle of rotation (θ1+θ2), where θ2 is the additional angle of rotation ( FIG. 9C ). It is noted that the original horizontal orientation of  FIG. 9A  is arbitrary, and other initial orientations can also be utilized. In one example and non-limiting embodiment, the first angle of rotation θ1 is approximately 70° and the additional angle of rotation θ2 is approximately 20°. 
     Functionally, the position of the lever handle  44  provides a visual indication of the status of the sidelight securing mechanism. That is, when the lever handle is in the first orientation (e.g., with the lever handle  44  substantially horizontal), an observer knows that the latch bolt  134  and the remote locking mechanisms  66  and  76  are fully engaged. If the lever handle  44  is in the second orientation (e.g.,  FIG. 9B ), the observer knows that only the latch bolt  134  is engaged but not the remote locking mechanisms  66  and  76 . Furthermore, for embodiments where the total rotational travel (θ1+θ2) is approximately 90°, use of lever handles  44  that are longer than the thumb knobs of the prior art is enabled because the interior frame members  32  do not interfere with their operation. The longer lever handle  44  enables easier visual confirmation of the status of the sidelight securing mechanism  20 . 
     Referring to  FIGS. 10 through 12 , the remote locking mechanisms are depicted in an embodiment of the invention. In one embodiment, the remote locking mechanisms  66  and  76  each include a latch hook  152  that extends from a remote lock housing  154  and are actuated by the operation bar  108 , which can be a single piece. Alternatively, a tongue version of the remote locking mechanism can be implemented. 
     The remote lock housing  154  includes two slider plates  156 , one on each side of the latch hook  152 . Each remote locking mechanism  66 ,  76  is driven by the respective tie bar  72  or  82 . The tie bar  72 ,  82  the drives two slider plates  156  inside the remote lock housing  154 , one on either side of the latch hook  152 . The latch hook  152  is pivotally mounted to a remote lock shaft  158  that is rigidly connected to the remote lock housing  154 . In one embodiment, a guide pin  162  extends laterally from both sides of the latch hook  152 , with the ends of the guide pin  162  engaging mirrored Z-shaped slots  164  formed on the slider plates  156 . As the tie bar  72 ,  82  drives the slider plates  156  parallel to the latch hook  152 , the guide pin  162  follows the Z-shaped slots  164  in the slider plates  156  and rotates the latch hook  152  to engage or disengage the strike plate  48  on the interior member  32  of the door frame  26 . 
     The Z-shaped slots  164  in the slider plates  156  enable over-travel of the tie bars  72  and  82  to accommodate tolerance variation in all of the components while still accurately controlling the extended and retracted positions of the latch hook  152 . This aspect is advantageous when using a one-piece operation bar  108 , as it helps ensure that the remote locking mechanisms  66  and  76  fully extend and retract without one remote lock preventing the other remote lock from fully extending or retracting by reaching the end of travel ahead of the other. By this design, use of a one-piece operation bar  108  is facilitated, rather than the two-piece operation bar design seen in existing patio door hardware. 
     References to relative terms such as upper and lower, front and back, left and right, or the like, are intended for convenience of description and are not contemplated to limit the invention, or its components, to any specific orientation. All dimensions depicted in the figures may vary with a potential design and the intended use of a specific embodiment of this invention without departing from the scope thereof. 
     Each of the additional figures and methods disclosed herein may be used separately, or in conjunction with other features and methods, to provide improved devices, systems and methods for making and using the same. Therefore, combinations of features and methods disclosed herein may not be necessary to practice the invention in its broadest sense and are instead disclosed merely to particularly describe representative embodiments of the invention. 
     For purposes of interpreting the claims for the present invention, it is expressly intended that the provisions of 35 U.S.C. §112(f) are not to be invoked unless the specific terms “means for” or “step for” are recited in the subject claim.