Apparatus for retaining a retractor mechanism in a lock assembly

A retainer apparatus including a retainer clip having a back component, a pair of side plate components, and a pair of front plate components that hold a retractor mechanism for extending and retracting a latch of a lock assembly. The retainer apparatus allows the retractor mechanism to be pre-assembled, ready for connection to a pre-assembled chassis of the lock assembly. One embodiment of the retainer clip is a single formed piece having a back component with at least one post for supporting a spring, side components to provide a bearing surface to slide the retractor mechanism, and front components angled inward to retain the retractor mechanism and the latch. A plurality of prongs extend from the retainer clip to receive the chassis of the lock assembly.

FIELD OF THE INVENTION

The present invention relates to a lock assembly. In particular, the invention relates to an apparatus for retaining a retractor mechanism used to extend and retract a latch of the lock assembly.

BACKGROUND OF THE INVENTION

Lock assemblies generally include a retractor mechanism attached to a latch or bolt and supported by a chassis mounted in a door. The retractor mechanism extends and retracts the latch to secure access through the door.

SUMMARY OF THE INVENTION

Typically, the retractor mechanism must be assembled and installed while building-up a chassis to support the lock assembly in the door. Likewise, removal of the retractor mechanism requires the disassembly of the chassis as well. The present invention provides an innovative design of a retainer apparatus for the retractor mechanism. The retainer apparatus of the invention allows the retractor mechanism to be pre-assembled before or after the chassis has been assembled. Manufacturers and installers of lock assemblies will find this innovative design less cumbersome when assembling and/or dissembling a lock assembly.

In one embodiment, the invention provides a retractor retainer apparatus for a retractor mechanism that extends and retracts a latch. One embodiment of the retainer apparatus is a clip that is operable to hold the retractor mechanism and the latch. The clip includes a back component having a first and second end, the back component having at least one post for mounting a spring to bias the retractor mechanism, a first side component having a first end connected to one end of the back component, and a second side component having a first end connected to the other end of the back component, wherein the first and second side components provide a bearing surface to slide the latch retractor mechanism, and a first front component connected to the second end of the first side component, and a second front component connected to the second end of the second side component, the first and second front components angled inward to form a narrowed gap that retains the latch retractor mechanism and allows extension and retraction of the latch to secure access through the door.

In another embodiment, the invention provides a door lock assembly for securing a door, the lock assembly including a retractor mechanism to linearly extend the latch to a locked position and to retract the latch to an unlocked position, a chassis to support the lock assembly in the door, and a retainer apparatus to hold the retractor mechanism, the retainer apparatus having a back component having at least one post for mounting at least one spring to bias the retractor mechanism, a first and a second side component each having one end connected to each end of the back component, said first and second side components providing a bearing surface for moving the retractor mechanism, a first and a second front component connected to the other ends of the first and the second side components, the front components angled inward to form a narrowed gap, wherein the retainer apparatus retains the retractor mechanism in the chassis.

Briefly summarized, the retractor retainer apparatus is a clip having a back component, a pair of side plate components, and a pair of front plate components that retains a retractor mechanism for extending and retracting a latch. The retainer apparatus allows the retractor mechanism to be pre-assembled, where this sub-assembly is ready for installation or connection to a partially or completely pre-assembled chassis of a lock assembly. One embodiment of the clip is a single formed piece that includes a back component having at least one post for mounting a spring to bias the retractor, side components to provide a bearing surface to slide the retractor for the latch, and front components angled inward to retain the retractor and engage the latch. A plurality of prongs extend from the clip to hold the clip to the chassis of the lock assembly. Manufacturers will find the sub-assembly of the retractor mechanism less cumbersome and time consuming when assembling and/or disassembling the lock assembly.

As is apparent from the above, it is an aspect of the invention to provide a retainer apparatus for a latch retractor mechanism that secures access through a door. Other features and aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.

DETAILED DESCRIPTION

FIG. 1illustrates a perspective view of a lock assembly4that includes a latch apparatus or retractor assembly6. One embodiment of the retractor assembly6includes a retractor or retractor mechanism8retained in a retainer apparatus10.

FIG. 2illustrates one embodiment of the retainer apparatus10for retaining the retractor mechanism8. As illustrated inFIG. 2, the retainer apparatus10includes a retainer clip having a back component15, a first20and a second25side component, and a first30and a second35front component. In one embodiment, the back component15, first20and second25side components, and first30and second35front components are machined-formed from a single metal plate (e.g., steel plate). In an alternative embodiment, the components of the retainer apparatus10can be created separately and inter-connected using any suitable means (e.g., spot-welded, soldered, etc.) known to those in the art.

As shown inFIG. 2, one embodiment of the back component15is a curvilinear-shaped metal plate. The curvilinear shape is designed to conform to the overall shape of the lock assembly4. In alternative embodiments, the back component15can include other shapes (e.g., bends, flat sides, etc.) suitable for the lock assembly4. Another embodiment of the back component15includes a pair of posts40and45. As shown inFIGS. 2 and 3, the posts40and45support the retractor mechanism springs50and55. One embodiment of the posts40and45are machined stamped or cut out from the back component15and angled in a direction inwardly with respect to or from the back component15. In another embodiment, the posts40and45can be separate components attached to the back component15using other suitable means (e.g., spot-welded) known to those in the art. In yet another embodiment, the posts40and45can be stamped or cut out from a portion of the back component15and each side component20and25. The back component15also includes a catch spring base60. The catch spring base60supports a catch spring biased against a catch of the retractor mechanism8(discussed later).

The first20and second25sides form the bearing surfaces for sliding the retractor mechanism8in a linear direction between an extended and a retracted position. As shown inFIG. 2, the first20and second25side components have one end connected to each end of the back component15. One embodiment of side components20and25are flat plates to support the linear sliding of the retained retractor mechanism8. Of course, the shape of the side components20and25can vary. The first20and the second25side components are designed to have some elasticity to enable installation of the retractor mechanism8.

As shown inFIGS. 2 and 3, the first30and second35front components constrain the retractor mechanism8against the back component15and the bias of the springs50and55.FIGS. 2shows one embodiment of the first30and the second35front components angled inward with respect to the ends of the first20and second25side components. The inward-angled front components30and35form a narrowed gap65. The width of the gap65is designed to constrain the retractor mechanism8, yet allow the extension and retraction of a latch or bolt70(FIG. 1) of the retractor mechanism8. The first30and second35front components are also designed with some flexibility for installing the retractor mechanism8.

FIG. 3shows a perspective view of the retractor mechanism8installed in the retainer apparatus10. The retractor mechanism8slides along the side components20and25to extend and retract the bolt70(FIG. 1). As shown inFIG. 3, one embodiment of the retractor-mechanism8includes a first105and a second carrier110, a pair of retractor bars115and120, and the pair of springs50and55. The retractor bars115and120include a pair of lips125and130that engage the bolt70. Drive shafts135and140(FIG. 1) include cams (not shown) designed to engage the first105and second110carriers. When rotating drive shaft135to retract the bolt70, the cams of the drive shaft135engages the first carrier105. The rotational force of the drive shaft135against the carrier105causes the retractor mechanism8to slide along the side components20and25against the bias of the springs50and55. Under the force of the drive shafts135and140, the retractor mechanism8retracts the bolt70. Upon release of the rotational force on the drive shaft135and140, the springs50and55bias the retractor mechanism8forward toward its original position. Thereby, the retractor mechanism8slides to extend the bolt70. The drive shaft140engages the carrier110in a similar manner as the drive shaft135.

As shown inFIG. 3, another embodiment of the retractor mechanism8further includes a catch141. The catch141engages a spring145compressed against the catch spring base60of the back component15, thereby biasing the catch141toward an extended position. The catch141is operable in holding a plunger bar (not shown) in a locked position.

FIG. 4illustrates a perspective view of a chassis200in support of the retractor mechanism8and retainer apparatus10. In one embodiment, the chassis200includes a first205and a second210side support for the retainer apparatus10. As shown inFIGS. 2 and 4, the retainer apparatus10includes a plurality of prongs240for receiving the first205and second210side supports of the chassis200. The prongs240can be one or more extensions at each end of a component and is not limiting on the invention. In one embodiment, the back component15includes two pairs of back prongs240band240dthat extend past the first20and second25side components (FIG. 3). Each pair of back prongs240band240dextends parallel with the ends of the back component15. In addition, one embodiment of the front components30and35include front prongs240a(FIG. 1) and 240cthat extend outward in a similar fashion past the first20and second25side plates. Similar to prongs240band240din relation to the back15, the front prongs240aand240cextend parallel with each end of the first30and the second35front plates. The back prongs240band240dand the front prongs240aand240dare located at opposite ends of the first20and second25side components and angled inward to receive the first205and second210side supports of the chassis200. One embodiment of the prongs240a–dare machine stamped or cutout from the first20and second25side components. Of course, the prongs240a–dcan be separate components attached using other suitable means (e.g., spot-welded, soldered, etc.) known to those in the art.

As shown inFIG. 4, the first205and second210side supports of the chassis200include reliefs250to receive the prongs240a–dof the retainer apparatus10. One embodiment of a relief250is a beveled edge at an angle compatible with the angle of the prongs240a–d.Of course, other shapes (e.g., channels) for a relief250in the side supports205and210of the chassis200can be used.

As shown inFIGS. 2–4, the retainer apparatus10allows the retractor mechanism8to be assembled individually from the build-up of the chassis200that supports the lock assembly4.FIG. 2illustrates one embodiment of the retainer apparatus10that is formed from machine pressing a metal plate. An operator pre-assembles the retractor assembly6by flexing the side components20and25, then inserting the retractor mechanism8inside the retainer apparatus10. Upon unflexing the side components20and25, the retractor mechanism is constrained.

Once the retractor assembly6is pre-assembled, the retractor assembly6can be inserted or connected to the chassis200as shown inFIGS. 1 and 4. In one embodiment, the chassis200is pre-assembled individually from the retractor assembly6. Upon individual assembly of the retractor assembly6and the chassis200, an operator can insert or slide the assembled retractor apparatus6, as shown by arrow255inFIG. 4, into an aperture258formed by the assembled chassis200. As described above, the prongs240a–dsecure the retractor assembly6to the chassis200. To disassemble the lock assembly4, the retractor assembly6can be removed from the chassis200without disassembling the retractor mechanism8and/or chassis200similar to the method for assembly described above. In one embodiment, an operator can slidingly remove the retractor assembly6from the reliefs250of the chassis200without disassembling the chassis200. Thereby, the design of the retractor mechanism8and retainer apparatus10of the invention is more versatile and less cumbersome to assemble and/or disassemble. In another embodiment, the retractor assembly6can be slid along the reliefs250when assembling the chassis200of the lock assembly4.

FIG. 1illustrates an exemplary embodiment of a lock assembly4with the retractor assembly6interconnected through an aperture258with an assembled chassis200. The chassis200includes a first260and a second265hub having openings for receiving the drive shafts135and140. The exemplary first hub260and second265hubs are mounted using screws270. Of course, other suitable connection means (e.g., spot-weld, cast, etc.) known in the art can be used. One embodiment of the chassis200is comprised of cast metal. Of course, the chassis200can be comprised of cast metal and/or one or more other suitable materials (e.g., forged metal, plastic) known in the art of lock assemblies.

Thus, the invention provides, among other things, a retractor assembly having a retractor mechanism retained in a retainer apparatus for connection to a chassis of a lock assembly. Various features and advantages of the invention are set forth in the following claims.