Knob retainer blocker mechanism

A door lock mechanism in which the outside knob is seamed against knob retainer, the retainer is diametrically slidable in the knob sleeve and has a specially shaped opening which defines a thrust-receiving edge for engagement by a spring which straddles a central area of the opening, and which has side borders which project toward each other and define blocker engaging surfaces between the legs of the spring. In a cylinder lock, a blocker plunger is preferably carried by a standard type bushing slidable in a standard supplemental cam sleeve, and the plunger is supported close to the retainer by the end wall of such cam sleeve. In a mortise lock, the plunger is similarly supported close to the retainer by a bushing in the knob sleeve.

This invention relates to door locks of the type having a knob on the 
outside of the door, and more particularly to mechanism for blocking the 
release of the retainer which secures the outside knob on its knob sleeve. 
In door locks having outside knobs, it is necessary to secure the knob 
against removal from the outside of the door, both to prevent loss of the 
knob and also to block unauthorized attempts to operate the lock by first 
removing the knob. When the outside knob contains a key-actuated core, 
this has in the past been accomplished by blocking the release of the knob 
keeper except when a proper key has been used to turn the key-actuated 
mechanism to a predetermined position. When the key-actuated mechanism is 
a key-removable core, the knob retainer has been made releasable only 
after such core has been removed. In Best et al U.S. Pat. No. 3,955,387, a 
key-removable core is connected to operate the lock through a throw member 
which blocks release of the knob retainer until both the core and such 
throw member have been removed. When the outside knob is a closed knob 
containing no key-controlled mechanism, these expedients are not 
available, and one common practice has been to secure the knob on the knob 
sleeve by a retainer which cannot be released without destroying the 
integrity of the knob or related parts of the mechanism. This has a number 
of disadvantages. Knobs cannot be replaced or interchanged when desired, 
and if a knob is damaged, it is not feasible to replace the knob without 
replacing a major portion or the entirety of the interconnected mechanism. 
The present invention overcomes this problem by blocking the release of 
the outside knob retainer at all times when the door is closed and locked, 
and provides for release of such retainer only after manipulation of parts 
of the lock from the inside of the door. This protects the outside knob 
when the door is closed, but provides for ready removal and replacement of 
the knob when there is proper access to the mechanism at the inside of the 
door. 
In accordance with the invention, the outside knob is retained by a 
retainer which for release must move inward transversely of the knob 
sleeve, and such movement is blocked by a blocking plunger or the like 
mounted in the knob sleeve. The plunger is desirably mounted inward of the 
retainer and is movable axially of the sleeve between an outward blocking 
position and an inward release position. The lock mechanism is so arranged 
that when the outside knob is locked, such blocking plunger will be held 
in its blocking position, and can be moved to its inward release position 
only by manipulation by parts of the lock at the inside of the door. 
In a cylindrical lock having an inner knob coaxial with the outer knob, it 
is conventional for some "functions" of the lock to provide the inner knob 
with a push button or turn button which, when actuated, will move a 
bushing in the outer knob sleeve to lock the outside knob and knob sleeve 
against operative rotation. In such lock sets, the blocking plunger of the 
present invention may be biased to its non-blocking position and moved to 
its blocking position by the same push button or turn button when that 
button is moved to lock the outside knob against rotation. In other 
functions of a cylindrical lock, the outer knob is permanently fixed 
against rotation, in which case the buttons may be used for purposes of 
the present invention without also controlling the rotation of the knob. 
Also, the blocker may be held in blocking position by the presence of an 
inside knob, and made releasable only when the inside knob is removed. 
In a mortise lock, it is known to provide the outside knob as part of a 
chassis assembly in which the knob is mounted on a supporting sleeve which 
is connected to a coaxial bolt-retracting hub by a spindle which is 
rotatable with and slidable axially of the knob sleeve, and to bias that 
spindle toward the hub so that it adjusts itself lengthwise to suit the 
relationship between the knob chassis and the hub, which varies with the 
thickness of the door. In accordance with the present invention, such an 
axially movable spindle is provided with a blocker nose at its outer end, 
and when the outside knob chassis assembly is mounted against the outside 
of the door, the spindle is moved to carry such blocker nose into blocking 
relationship with the knob retainer to prevent release of that retainer. 
The outside knob chassis is secured by bolts accessible only from the 
inside of the door, and release of the outside knob will be obtained by 
release of those clamping screws to allow the outside knob chassis to move 
away from the mortise case at least far enough to allow axial movement of 
the spindle and its blocker nose to a position in which the blocker nose 
is withdrawn from the knob retainer and permits that knob retainer to be 
retracted to a knob-releasing position.

The cylindrical lock shown in FIGS. 1 and 2 as mounted in a door 10 
comprises a chassis having end plates 12 and 14 defining a housing for a 
retractor 16 connected to retract the tailpiece 18 of a latch tube 
assembly 20. The inside chassis side plate 12 carries a tubular hub 22, 
externally threaded for the reception of a trim ring or rose 24. A knob 
sleeve 26 for the inside knob 28 is rotatably mounted in the hub 22 and 
projects therebeyond to support the knob 28. Its inner end carries a 
roll-back cam 27 for retracting the retractor 16. The knob preferably has 
a neck portion 30 which telescopes over the outer end of the hub 22 and is 
received within a collar on the rose assembly 24. The knob 28 is a hollow 
knob with a large end opening closed by a face plate 32 which is pressed 
in place against a drive ring 34 in a manner which locks the face plate in 
the end opening of the knob, as shown in U.S. Pat. No. 3,955,387. The 
drive ring 34 drivingly connects the knob 28 to the outer end of the knob 
sleeve 26 by tabs which extend into end notches in that knob sleeve and 
are outwardly separable therefrom. The inside knob 28 is retained in place 
by a knob retainer 36 transversely slidable in the knob sleeve and biased 
to a projected position by a biasing spring 38, and manually retractable 
with a tool inserted through an access hole 37. The biasing spring is like 
that shown in FIG. 2 and described below in connection with the outer knob 
retainer. The end face 32 contains a push button 40 biased outward and 
manually operable to actuate a locking bar 42 for locking the outside 
knob, as will be described. 
The outside chassis side plate 14 carries a fixed hub 52, externally 
threaded for the reception of a trim ring or rose assembly 54. An outer 
knob sleeve 56 for an outer knob 58 is rotatably mounted in the hub 52 and 
has at its inner end an out-turned roll-back cam (not shown in this 
section) for camming the retractor 16 rearward to retract the bolt of the 
latch bolt assembly 20. A neck portion 60 of the knob telescopes over the 
hub 52 and lies within a collar on the rose 54. The knob 58 is a hollow 
knob formed with a large end opening, and such opening is closed with an 
end plate 62 pressed into place against a drive plate 64 having inner tabs 
engaged in notches in the end of the knob sleeve 56 to drivingly connect 
the knob to the knob sleeve. The knob is held on the knob sleeve by a knob 
retainer 66 mounted transversely of the knob sleeve in diametrically 
opposite slots therein and having a projecting lug portion 68 with a 
bevelled end which engages behind the radial face 81 of an internal rabbet 
groove at the juncture between the hand-hold portion of the knob 58 and 
the neck 60. The retainer 66 is biased to engaged position by a spring 70. 
As shown in FIG. 2, the retainer 66 is formed with a central opening 72, 
and the spring 70 is a generally U-shaped spring similar to that shown in 
co-pending application Ser. No. 163,472, filed June 27, 1980, now U.S. 
Pat. No. 4,342,478, issued Aug. 3, 1982. Such spring has a hooked bight 
portion 74 interengaged with and against a forward thrust-receiving border 
76 of the opening 72 and having legs 78 extending in splayed relation 
across the knob sleeve 56 into engagement with forwardly diverging inner 
side faces of that knob sleeve. The legs are stressed to exert force 
outward against such surfaces and thereby cam the spring toward the 
thrust-receiving border 76 and thereby bias the knob retainer 66 to its 
knob-retaining position as shown. Opposite the end of the knob retainer 
lug 68, the neck 60 of the knob is formed with an access opening 80 
through which a tool may be inserted against a flat on the end of the lug 
to push it inward against the bias of the spring to a retracted, 
knob-releasing position. When the knob is locked against rotation, as when 
the door is closed and locked, such retraction of the knob retainer is 
blocked, as will be described. In the relationship of the parts as shown 
in full lines in FIG. 1, however, the knob is free to be turned to retract 
the bolt, and such blocking action does not occur. 
The inner end of the knob sleeve 56 contains a supplementary roll-back cam 
sleeve 82 having an out-turned roll-back cam 84 at its inner end in 
position to cam the retractor 16 rearward. For purposes of the present 
invention, the arrangement is such that the supplemental cam sleeve 82 and 
the knob sleeve 56 rotate together. 
For purposes of locking the outside knob 58 and its knob sleeve 56 against 
rotation, a bushing 88 is slidably mounted within the knob sleeve 56, in 
this case, in the supplementary cam sleeve 82. The inner end of the 
bushing 88 is of reduced diameter and carries a locking finger 90 which, 
in the position shown, extends outward across the end of the knob sleeve 
56 into a notch 92 formed at the base of the outside hub 52. In this 
position, it lies across a flat end portion of the knob sleeve 56, in 
clearance relation therewith, so that such knob sleeve 56 is free to 
rotate relative to the hub 52. Movement of the bushing 88 and its locking 
finger 90 axially from its full-line position to the dotted-line position 
shown will carry such locking finger into a notch 94 in the end of the 
knob sleeve 56, and thereby lock that knob sleeve 56 to the fixed hub 52. 
The knob sleeve 56 and the outside knob 58 will then be locked against 
rotation, as is known in the art. 
In accordance with the present invention, the bushing 88 carries at its 
inner end a cylindrical plunger 96, held by a pin 86. The plunger lies 
clear of the knob retainer 80 when the bushing 88 is in its retracted 
position shown in full lines in FIG. 1. When the bushing 88 is moved to 
its knob-locking position, such plunger moves to a blocking position in 
which it extends through the knob retainer 66, as shown in dotted lines in 
FIG. 1 and in cross section in FIG. 2. The central opening 72 in the knob 
retainer 66 has its side borders formed with inward projections which 
define inner cylindrical faces 98 in position to engage the projected 
plunger 96 to block movement of the knob retainer to a knob-releasing 
position and thus to prevent the knob keeper 66 from being thrust inward 
toward a knob-releasing position. 
In the cylindrical lock as shown in FIGS. 1 and 2, the position of the 
bushing 88 and the blocking plunger 96 is controlled by the push button 40 
in the inside knob 28. Such push button is connected to a locking bar 42 
which extends into thrust relation with the bushing 88. Both such button 
40 and bushing 88 are biased toward retracted position by biasing springs, 
as shown, and will normally be in their retracted positions as shown in 
full lines in FIG. 1. When the push button 40 is thrust inward, the 
locking bar 42 is moved endwise to move the bushing from its release 
position shown in full lines in FIG. 1 to its knob-locking position shown 
in dotted lines. In such position, the locking finger 90 locks the knob 
sleeve 56 to the hub 52 to prevent knob rotation, and the blocker plunger 
96 projects through the opening 72 in the knob retainer 66 so as to lie in 
the path of the shoulders 98 of the knob retainer and prevent retraction 
of that knob retainer. For purposes of holding the bushing 88 and blocker 
plunger 96 in actuated position, the locking bar 42 is provided with a 
pair of nose cams 102 which ride across the edges of a catcher plate 104 
carried by the retractor 16. The catcher plate 104 is spring-pressed 
toward the bar 42, and when such nose cams pass the edges of the catcher 
bar, such edges drop into notches behind the nose cams so as to lock the 
locking bar 42 in advanced position. 
Installation of the cylindrical lock set embodiment shown in FIGS. 1 and 2 
is carried out by adjusting the outside trim ring or rose 54 along the 
threads of the outside hub 52 to properly locate the retractor 16 in 
alignment with the latch tube 20, and locking the rose 54 in adjusted 
position as by a pin 106 carried by the chassis in known manner. The 
chassis, with the inside knob 28 and inside rose 24 removed, is then 
installed through the transverse opening in the door and brought into 
proper interengagement with the latch tube 20 and tailpiece 18. The inside 
rose 24 is then threaded onto the inside hub 22, to fix the chassis in 
place with the door clamped between the two roses 24 and 54. Removal can 
then occur only by reversing this procedure and removing the rose 24 at 
the inside of the door. The outside knob 58 is installed on the outside 
knob sleeve 56, by sliding the neck of the knob over the end of the knob 
sleeve, in proper orientation to bring its drive ring 64 into interlocking 
engagement with the notches at the ends of the knob sleeve. As the knob 
engages the bevelled outer face of the lug 68 of the knob retainer 66, 
that retainer will be cammed inward against the bias of its spring, and 
the knob neck will pass across the retainer until the lug 68 passes the 
bottom end face 81 of the rabbet groove 69, and the retainer 66 will then 
be moved outward to overlie such face and lock the knob in retained 
position on the sleeve. The inner knob 28 is similarly mounted on the 
inner knob sleeve 26. 
With the button 40 in its outward position relative to the inner knob 28, 
as shown in full lines in FIG. 1, the locking rod 42 will be withdrawn, 
and the bushing 88 in the outer knob sleeve will be in its retracted 
position so that the locking finger 90 will be disengaged from the notch 
94 in the outer knob sleeve 56, and the outer knob will be rotatable to 
cam the retractor 16 rearward and retract the bolt. With the bushing 88 in 
retracted position as shown in full lines, the blocker plunger 96 will 
also be in retracted position, substantially disengaged from the knob 
retainer 66. Under these conditions, with the outer knob operable to 
retract the bolt, it is feasible to leave the knob retainer 66 unblocked 
and operable to release the knob from the knob sleeve. 
When the outer knob is locked against rotation, by manually pushing the 
button 40 inward, the inward movement acts through the locking rod 42 to 
move the bushing 88 to its actuated position, to the right in FIG. 1, as 
shown in dotted lines. This carries the locking finger 90 axially into the 
groove 94 of the outer knob sleeve 56 to lock that knob sleeve to the 
stationary hub 52 and lock the sleeve and knob against rotation. 
Concurrently, the movement of the bushing 88 carries the blocking plunger 
96 through the plane of the knob retainer 66 to its blocking position as 
shown in dotted lines in FIG. 1 and in full lines in FIG. 2. The plunger 
then blocks the knob retainer 66 against inward movement, and it is then 
not possible to release the outer knob 58 for removal from the knob 
sleeve. In order to remove the outer knob, it is first necessary to 
manipulate part of the mechanism at the inside of the door, in this case 
to release the push button 40 as by rotating the inside knob 28, and allow 
such button, the locking bar 42, the bushing 88, and the blocking plunger 
96 to move to their retracted, full-line positions shown in FIG. 1. The 
knob retainer 66 then becomes unblocked and the outer knob 58 can be 
removed by thrusting the knob retainer 66 inward by a suitable tool 
inserted through the opening 80. 
In the modification shown in FIG. 3, the large end opening in the inside 
knob 128 is completely closed by an end face 132. When such knob is 
mounted on the inside knob sleeve 126, the end face 132 of the knob comes 
into engagement with a cup 140 mounted on the end of the locking bar 42 so 
as to move that bar from its retracted position as shown in full lines in 
FIG. 1 to its actuated position shown in dotted lines in FIG. 1. This has 
the effect of moving the blocking plunger 96 into the plane of the outside 
knob retainer 66 where it will block the retraction of that retainer and 
prevent removal of the outside knob 58. In this modification, the locking 
bar 42 and the blocking plunger 96 are in their blocking position at all 
times when the inside knob 128 is in operative position on the inside knob 
sleeve 126. Removal of the ouside knob 58 can then occur only by first 
removing the inside knob 128, which allows the locking bar 42 and cup 140 
to move outward from the positions in which they are held by the end face 
132 of the outside knob, and hence permits the blocking plunger 96 to move 
to a retracted position where it will permit actuation of the outside knob 
retainer to release the outside knob for removal. 
The mortise lock embodiment shown in FIGS. 4 and 5 comprises a mortise case 
110 mounted in the edge of a door 112 and providing a latch bolt 114 and a 
dead bolt 116. The lock set includes an outside escutcheon 118 through 
which a key-operated lock cylinder 120 is mounted to actuate both the dead 
bolt and the latch bolt 114. An inside escutcheon 122 carries a turnknob 
124 connected to operate the dead bolt. The mechanism of the mortise case 
also includes a pair of coaxial hubs 126 rotatably mounted by end collars 
received in openings in the side walls 127 and 129 of the case 110. The 
mortise lock mechanism may be any of a number of conventional mechanisms, 
and the details are not necessary to an understanding of the present 
invention. As is known, the hubs 126 are connected to operate retracting 
mechanism for the latch bolt 114, and such mechanism may include 
deadlocking mechanism controlled by an auxiliary latch 128 which is 
depressed by the strike plate when the door is closed. 
The two hubs 126 are connected for operation by inside and outside knob 
assemblies. The inside knob assembly includes a chassis comprising a hub 
130 fixed to a side plate 132 adapted to be secured against the inside 
face of the door and covered by the escutcheon 122. The hub is externally 
threaded for the reception of a trim ring 134. An inside knob sleeve 136 
is mounted for rotation within the hub 130. As shown, such knob sleeve 136 
is formed as an assembly of a bushing 135 having a reduced end journalled 
in the hub 130 and having an outer end which is received in a cylindrical 
sleeve portion 137 which is pinned to the bushing 135 by a pin 138. An 
inside knob 140 is mounted by its neck portion 142 on the knob sleeve 136. 
The outer end of the knob is closed by an end face 144 which is pressed 
into place against a drive ring 146 which transmits torque between the 
knob and knob sleeve. The knob is held in place on the knob sleeve by a 
retainer 148 biased outward into overlying relation with a circular 
shoulder formed inside the neck, and the neck has a tool insertion opening 
152 for insertion of a tool to force the retainer 148 inward to release 
the inside knob for removal from this knob sleeve. 
The knob sleeve 140 and knob sleeve 136 are connected to the adjacent 
mortise case hub 126 by a square spindle 154. This is slidable in a 
conforming opening in the bushing 135, and is spring-pressed inward toward 
and into engagement with the hub 126 by a spring 156 acting between the 
inner end of the bushing and a snap ring 158 fixed in a groove in the 
spindle. This general method of mounting a spindle in a mortise lock is 
known, and provides a self-aligning and self-adjusting connection between 
the knob assembly and the mortise case adapted to accommodate different 
thicknesses of doors and tolerances which occur in installation 
procedures. Accordingly, the spindle 154 has a normal position, when 
disengaged from a mortise case, in which it extends substantially farther 
out of the knob assembly and in which it is held by a retainer snap ring 
159 engaged in a notch in the turned end of the spindle. 
The outer knob assembly comprises a chassis including a hub 160 fixed to an 
end plate 162 adapted to be secured against the outside face of the door. 
The outside of the hub is threaded for the reception of a trim ring 164. A 
knob sleeve 166 is rotatably mounted in the hub 160 and comprises a 
bushing 165 having its inner reduced end journalled in the hub and having 
an outer larger end which is received within the inner end of a 
cylindrical sleeve 167. The two are pinned together by a drive pin 168. An 
outside knob 170 is mounted on the knob sleeve 166 by a neck portion 168 
which is telescoped over the outer end of the hub and is surrounded by the 
outer end of the trim ring 164. A large end opening in the knob 170 is 
closed by a face plate 174 which is pressed into place against a drive 
ring 176 which has inward-extending fingers engaged in notches in the 
outer end of the knob sleeve for transmitting torque between the knob 170 
and the knob sleeve 166. The knob is held in place on the knob sleeve by a 
retainer 178 mounted for transverse movement in diametrically opposite 
slots through the wall of such sleeve. The retainer is biased by a biasing 
spring 179 in a direction to engage its outer end over a circular shoulder 
180 formed in the neck portion 168 of the knob. An access opening 182 in 
the knob neck permits insertion of a tool to retract the retainer 178. The 
knob and knob sleeve are operatively connected to the adjacent hub 136 of 
the mortise case by a square spindle 184 which, like the inside spindle, 
is slidable in the bushing 165 and spring-pressed toward and into 
engagement with the hub 126 by a spring 186. 
In accordance with the present invention, the outer end of the spindle 184 
for the outside knob carries a blocker nose 190 which, in the normal 
position of the spindle when the lock set is mounted to a door as shown, 
projects from that spindle 184 through a central opening 192 in the 
outside knob keeper 180. As shown in FIG. 5, such opening 192 is defined 
by side borders which have inward projections 194 extending toward each 
other to define portions of a cylindrical surface which lie in close 
proximity to the side of the blocker plunger 190 and effectively block 
retraction of the knob retainer 178 from its knob-retaining position as 
shown in FIG. 4. When the outside knob assembly is separate from the door 
and an associated mortise case, the spring 186 moves the spindle 184 
outward from the outside knob sleeve 166, and carries the blocker plunger 
190 out of the plane of the knob retainer 178 so that that knob retainer 
can be retracted for mounting a knob 170 on the knob spindle 166 and for 
removing the knob from that spindle. 
The two knob assemblies are held against the face of the door by bolts 
which include an internally threaded sleeve 196 fixed to the base plate 
162 of the outside knob chassis. Such internally threaded sleeves 196 on 
the outside chassis receive screws 198 inserted through the base plate 132 
of the inside knob assembly and which are accessible only from the inside 
of the door. 
Installation of a mortise lock embodiment of the invention as shown in 
FIGS. 4 and 5 involves mounting the mortise case in a suitable mortise in 
the edge of the door in the usual way. An outside knob and escutcheon 
assembly is then prepared with the escutcheon engaged loosely over the hub 
160 and the trim ring 164 threaded loosely on that hub. Also, a knob 170 
is mounted on the knob sleeve 166. With this outside knob and escutcheon 
assembly still separate from the door and mortise case, the spindle 184 is 
in its outermost position so that it moves the blocker plunger 190 out of 
the plane of the knob retainer 178, and this leaves that retainer operable 
to install and remove the knob from the knob spindle. The knob is 
installed by pushing it onto the outer end of the knob sleeve 166. When it 
engages the retainer, bevelled faces on the retainer and knob cause the 
retainer 178 to be cammed inward to pass the knob onto the sleeve until 
the retaining shoulder 180 passes the retainer, and the retainer is then 
moved outward by its biasing spring into its retaining position as shown 
in full lines in FIG. 4. For removal, a suitable tool is inserted through 
the opening 182 to force the retainer 178 inward to a knob-release 
position, but this can occur only when the blocker nose 190 is withdrawn 
from the retainer. 
With the outside knob and escutcheon assembled as indicated, the assembly 
is then brought against the outside face of the door, and its bolt sleeve 
portions 196 passed through suitable openings in the mortise case. An 
inside knob chassis is then mounted against the inside face of the door, 
and screws 198 are threaded through the base plate 132 into the threaded 
sleeves 196 to clamp the two face plates solidly against the sides of the 
door. The inside trim assembly is then completed by installing the 
escutcheon 122, the trim ring 134, and the knob 140. The key-operated 
cylinder 120 may be installed in the usual way after the installation of 
the escutcheons. 
As the outside knob assembly is thus assembled to the door, the spindle 184 
comes into engagement with the adjacent mortise hub 126, and is forced 
outward of the door and inward of the knob sleeve 166 to carry its blocker 
nose 190 into blocking position through the plane of the outside knob 
retainer 178, and such retainer is then blocked from moving to release 
position and the knob 170 is securely locked against removal. 
Removal of the outside knob then requires a reversal of the installation 
procedure, and manipulation of lock mechanism at the inside of the door 
before the outside knob 10 can be removed from its knob spindle. Thus, by 
removing the inside knob 140, the trim ring 134, and the escutcheon 120, 
access is obtained to the screws 198 which secure the inside and outside 
chassis assemblies against the face of the door. Those screws are then 
released and the outside escutcheon 118 is released from the face of the 
door, so that the outside knob and escutcheon assembly can be moved away 
from the door sufficiently to allow the spindle 184 to move axially 
relative to the knob retainer 178 a sufficient distance to unblock the 
operation of that knob retainer. The retainer can then be moved to a 
knob-release position with a tool inserted through the access opening 180, 
and the outside knob can then be removed from its knob sleeve 166.