Passive door bolt assembly

A bolt assembly for securing a passive door panel relative to an entryway frame. The bolt assembly has a base to be fixedly mounted relative to the passive door panel, a catch attached to the base with a leaf spring to deflect relative to the base, and a bolt which is able to translate relative to the base between a retracted position and an extended position for securing the passive door panel. The bolt is biased toward the extended position and selectively maintained in the retracted position by the catch.

FIELD OF THE PRESENT DISCLOSURE

The present disclosure relates to bolts, particularly slide bolts, used to secure a passive door of a double door entryway.

BACKGROUND

French door, or double door, entryway units are popular in commercial and residential settings for their pleasing aesthetics and functional practicality. The optional ability to open a secondary (i.e. passive) door panel greatly increases the ability for ingress and egress of persons and household items.

As seen inFIG. 1, a French door entryway10traditionally includes a passive door panel12, and an adjacent active door panel14. The sets of door panels may swing inwardly (as shown inFIG. 1) into the structure (so-called “inswing” doors), or may swing outwardly from the structure (so-called “outswing” doors). The passive door panel12typically includes an astragal16mounted along the entire extent of a non-hinged vertical edge (stile) of the passive door panel. In its most simple form, the astragal16may be little more than molding attached to the passive door panel12to act as a stop for the active door panel14. More recently, astragals16have taken the form for assemblies mounted to the stile of the passive door panel12, which have a significant role in the structural and environmental resistance performance of the entryway10. The astragal16has a role in securing the passive door panel12in place, and often includes seals to prevent the infiltration of moisture into the building.

To secure the passive door panel12in a closed position, the astragal16may be provided with hardware18, such as sliding bolts, adjacent to a top and bottom of the passive door panel. The hardware18typically engages a frame19of the entryway. The frame may have a header20spanning the top of the entryway10and a threshold22(also referred to as a door sill) spanning the bottom of the entryway. Hardware18mounted near the top of the passive door panel would extend upward to engage the header20, and hardware mounted near the bottom of the passive door panel would extend downward to engage the threshold22.

Improper assembly or installation of an entryway10can create conditions where the hardware18is prevented from moving into its fully engaged position. This can lead to reduced strength under wind loads and to sub-optimal compression of sealing components. Therefore, designers continue to make improvements to the hardware18to provide a more secure, robust and consistent device for maintaining the passive door panel12in a closed position.

SUMMARY

Some embodiments of the present disclosure describe a bolt assembly configured to secure a passive door panel relative to an entryway frame. The bolt assembly comprises a base configured to be mounted to the passive door panel or an astragal on the passive door panel. The base is configured to be fixed relative to the passive door panel. A catch is attached to the base with a leaf spring so that the catch can deflect relative to the base between an engagement position and a release position. The catch is biased toward the engagement position. The catch comprises an actuation button and a keeper. A bolt is configured to translate relative to the base between a retracted position and an extended position. The bolt comprises a slide having a pocket. The keeper is configured to engage the pocket to retain the bolt in the retracted position. A pin is attached to the slide for movement therewith. The pin is configured to engage the entryway frame when the bolt is in the extended position. A spring is configured to bias the bolt to the extended position. If the bolt is in the retracted position, pressing upon the actuation button would deflect the catch to the release position, the catch would disengage from the pocket, and the spring would push the bolt to the extended position.

Other embodiments of the present disclosure describe astragals configured to secure a passive door panel relative to an entryway frame. An exemplary astragal comprises an astragal body having a channel running along a length of the astragal body, and a bolt assembly. The bolt assembly includes a base fixed relative to the astragal body and a bolt configured to slide relative to the base between a retracted position and an extended position. A spring is located between the base and the bolt. The spring is configured to bias the bolt to the extended position. A catch is attached to the base with a leaf spring for retaining the bolt in the retracted position. If the bolt is in the retracted position, deflecting the catch releases the bolt to slide to the extended position.

Yet another embodiment of the present disclosure describes an astragal configured to be mounted to a passive door panel. The astragal comprises an astragal body having a channel running along a length of the astragal body, a trim cover mounted to the astragal body to at least partially enclose the channel, a first bolt assembly arranged adjacent to a bottom end of the astragal body, and a second bolt assembly arranged adjacent to a top end of the astragal body. The first bolt assembly comprises a base fixedly mounted within the channel, a catch attached to the base with a leaf spring to deflect relative to the base between an engagement position and a release position, the catch biased toward the engagement position. The catch comprises an actuation button and a keeper. The first bolt assembly also comprises a bolt configured to translate relative to the astragal body between a retracted position and an extended position relative to the astragal body. The bolt comprises a slide having a pocket, the keeper configured to engage the pocket to retain the bolt in the retracted position. A pin is attached to the slide for movement therewith, the pin configured to engage an entryway frame when the bolt is in the extended position. A spring is configured to bias the bolt to the extended position. A pull is pivotably mounted to the slide for use when returning the bolt to the retracted position. A lock block configured to translate relative to the base and the bolt, and having one or more sealing pads fixed to the lock block, is provided as part of the first bolt assembly. A compression spring is operable between the bolt and the lock block of the first bolt assembly. The second bolt assembly does not include a lock block, but instead includes a guide block fixedly mounted adjacent to the top end of the astragal body, the guide block having a passage through which the pin is configured to slidably extend.

These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiments, when considered in conjunction with the drawings. It should be understood that both the foregoing general description and the following detailed description are explanatory only and are not restrictive of the invention as claimed.

DETAILED DESCRIPTION

Exemplary embodiments of this disclosure are described below and illustrated in the accompanying figures, in which like numerals refer to like parts throughout the several views. The embodiments described provide examples and should not be interpreted as limiting the scope of the invention. Other embodiments, and modifications and improvements of the described embodiments, will occur to those skilled in the art and all such other embodiments, modifications and improvements are within the scope of the present invention. Features from one embodiment or aspect may be combined with features from any other embodiment or aspect in any appropriate combination. For example, any individual or collective features of method aspects or embodiments may be applied to apparatus, product or component aspects or embodiments and vice versa.

Turning toFIGS. 2 and 3, front and rear perspective views of a bolt assembly30are provided. The bolt assembly30includes an anchoring base32, hereafter base32. In one embodiment, the base32is used to mount the bolt assembly30to a passive door panel12. For example, a mortise may be provided on the non-hinged stile of the passive door panel12to receive the bolt assembly30. In a preferred embodiment, the bolt assembly30is combined into an astragal as discussed below and shown inFIG. 9. In this embodiment, the base32may be used to securely position the bolt assembly30as part of the astragal. The base32would be fixedly mounted relative to the passive door panel12to swing with the door panel and avoid relative movement between the passive door panel12and the base.

FIG. 4shows a rear perspective view of the base32according to one embodiment. The base32includes a face plate34extending along a longitudinal axis A. The longitudinal axis A will generally run parallel with a height direction of the passive door panel12. The height direction may correspond with the Z axis shown inFIG. 1relative to the entryway10. A first boss36extends from the face plate34in a rearward direction. A forward/rearward direction is defined perpendicular to the stile of a door panel, the forward direction being away from the door panel and the rearward direction generally toward the door panel. When the passive door panel12is closed, the forward/rearward direction corresponds with the X-axis shown inFIG. 1.

The first boss36may include one or more fastener holes38to accommodate fasteners, such as screws, used to mount the base32relative to the passive door panel12or the astragal. The fastener holes38may generally extend perpendicular to the face plate34and the longitudinal axis A. Therefore the fastener holes38extend along the forward/rearward direction. The first boss36may also accommodate a guide bore40. The guide bore40has a central axis substantially parallel with the longitudinal axis A.

The face plate34of the base32may include an aperture42extending through the face plate. The aperture42is configured to receive a portion of a catch for use in actuating the bolt assembly30. Adjacent to the aperture42, a second boss44may extend rearwardly from the face plate34. The second boss44includes a retention cavity46formed therein. The retention cavity46may be best seen inFIG. 8. The retention cavity46is sized and shaped to retain the catch for the bolt assembly30.

Having described the base32according to one embodiment, one of ordinary skill in the art will appreciate suitable alternatives within the scope of the present disclosure for securing the bolt assembly30in a fixed position relative to the passive door panel12. For example, fastener holes38may be fewer or greater in number. The fastener holes38may be provided at locations other than the first boss36. Further, support structure for the fastener holes38, guide bore40and retention cavity46may be provided without distinct bosses if the base32is sufficiently structurally strong. In other embodiments, the base32may be mounted relative to the passive door panel12by means other than screws, such as a snap fit with integrated or attached clips.

Returning briefly toFIGS. 2 and 3, the bolt assembly30also includes a bolt50attached to the base32. The bolt50is attached to the base32in a manner that allows the bolt50to translate relative to the base32. As a result, in use, the bolt50is able to selectively translate relative to the passive door panel12between a retracted position and an extended position. As commonly understood in the art of shoot bolt hardware, the retracted position includes an engagement end52of the bolt50positioned substantially at or inward of a respective top or bottom edge of the passive door panel12. The extended position, on the other hand, involves the engagement end52of the bolt50extending outward beyond the respective upper or lower edge of the passive door panel12into engagement with a header20or a threshold22respectively.

FIGS. 5 and 6show front and rear views of the bolt50respectively. The engagement end52may be provided by a pin54. The pin54has a longitudinal pin axis P which will be substantially parallel with the longitudinal axis A of the base32when the bolt assembly30is assembled. The pin54is preferably a strong metal, such as steel, to provide strength while the pin is engaged with the entryway10.

In the illustrated embodiment, a slide60, formed from a polymer, is overmolded onto the pin54. In other embodiments the pin54and the slide60may be formed as a unitary, integral component formed from metal or plastic. The slide60may include a post62. A tip64of the post62may have sprung barbs66. This configuration allows the bolt50to attach to the base32by inserting the post62into and through the guide bore40as seen inFIG. 3. Once attached, the sprung barbs66prove a stop, maintaining attachment between the post62and the base32while providing a limit on relative translation between the base32and the bolt50.

As seen inFIG. 6, the slide60also includes a retention pocket68. The retention pocket68is used to selectively maintain the bolt50in the retracted position. Retention of the slide60will be discussed further below with respect toFIG. 8.

In some embodiments, one or more flanges70may be provided along the length of the slide60. The flanges70extend perpendicular to the longitudinal pin axis P. The flanges70can help position and retain the slide60within an astragal as discussed below. The flanges70may be continuous along some or all of the length of the slide60. Alternatively, as shown, the flanges70may be provided as various segments along the slide60.

In the illustrated embodiment, the bolt50also includes an interface72located on an opposite end of the slide60from the pin54. The interface72is accessed by a user to manually return the bolt50from the extended position to the retracted position. Various structures may be provided to assist the user with gripping and translating the bolt50. Projections may act as handles. Alternatively, grooves or apertures may be configured to assist with manipulation of the bolt50with the user's finger(s). In one embodiment, the interface72includes a pivoting pull tab74. The pull tab74may be pivotably connected to a body portion76of the slide60. The pull tab74is pivotable between a closed position, with the pull tab substantially recessed within the body portion76, and an open position, where the pull tab extends forward away from the stile of the passive door panel. The pull tab74may include beveled portions78. If an active door panel14is being closed while the pull tab74is in the open position, the active door panel can pivot the pull tab rearward toward the closed position and out of the way of the closing active door panel by pushing upon one of the beveled portions78.

Back inFIGS. 2 and 3, a spring90, such as a coil spring, is shown supported by the post62and retained between the slide60and the base32. The spring90is a compression spring. The spring90is arranged between the bolt50and the base32to bias the bolt toward the extended position with the engagement end52of the bolt50a maximum distance from the base32.

To selectively retain the bolt50in the retracted position, and provide resistance to the desired extension caused by the spring90, a catch100is attached to the base32. The catch100is shown in more detail inFIG. 7. The catch100includes an actuation button102in the form of a projection arranged to correspond with the aperture42through the face plate34of the base32. Thus, the aperture42provides access for a user to press against the actuation button102and deflect the catch100relative to the base32.

The catch100also include a keeper104configured to engage the retention pocket68of the slide60to hold the bolt50in the retracted position. The keeper104includes a tapered leading edge106. While the bolt50is being retracted, the retention pocket68contacts the tapered leading edge106of the catch100to deflect the catch relative to the base32until the catch mates with the interior of the retention pocket.

Retention of the slide60by the catch100may be best understood in view of the cross section shown inFIG. 8. First, the catch100is attached to the base32by a leaf spring110. The leaf spring110biases the catch100forward to an engagement position where the actuation button102extends through the aperture42of the base32. One end of the leaf spring110is press fit into the retention cavity46of the base32. The other end of the leaf spring110may engage a notch112along the rear side of the catch100. In the engagement position shown, the keeper104of the catch100is configured to engage with the retention pocket68of the slide60when the bolt50is in the retracted position.

As should be understood, to release the bolt50from the retracted position to the extended position, the user deflects the catch100to a release position relative to the base32. Deflection of the catch100is in opposition to the biasing force provided by the leaf spring110. By pressing upon the actuation button102, the keeper104is disengaged from the retention pocket68. The spring90is then free to push the bolt50toward the extended position.

To return the bolt50to the retracted position, the slide60is manually retracted with the user interface72. A protrusion or leading wall114forming the retention pocket68is configured to displace the catch100relative to the base32by pressing upon the tapered leading edge106of the keeper104. The leading wall114may similarly have a chamfered edge116to further assist with displacement of the catch100as the slide60approaches the retracted position.

Turning toFIG. 9, a partial cut-way view is provided that shows the bolt assembly30mounted at the lower end of an astragal assembly150. The astragal assembly150includes an astragal body152. The astragal body152may be an extrusion, such as an aluminum extrusion. The astragal body152provides a mounting side154for attachment to the stile of the passive door panel12and a front side156configured to face the free stile of the active door panel14when the active door panel is closed.

The astragal body152defines a channel158running along a length of the astragal body. The length of the astragal body152corresponds with the height of the passive door panel12when the astragal assembly150is attached to the passive door panel.FIG. 9shows the bolt assembly30mounted at least partially within the channel158. The illustrated bolt assembly30ofFIG. 9is shown adjacent to the bottom end of the astragal body152. The bolt assembly30may be assembled along the channel158by insertion into one of the ends of the astragal body152. In another embodiment, the bolt assembly30is sized and shaped such that the bolt assembly can rotate into the channel158at the desired location through the gap160in the face of the channel158.

The illustrated bolt assembly30ofFIG. 9includes an optional lock block170. The lock block170can also be seen inFIGS. 2 and 3. The lock block170includes a central passage172(seeFIG. 3) through which the pin54extends. The lock block170may also include at least one leg174for attachment of the lock block170to the slide60. The lock block170is configured to be able to translate relative to the bolt50and the base32. In other words, the pin54is configured to slide relative to the central passage172and the lock block170is not fixedly mounted to the passive door panel12or the astragal body152.

FIG. 3shows a compression spring176operable between the slide60and the lock block170. The compression spring176seeks to force the lock block170toward the engagement end52of the bolt50. When the bolt50is released toward its extended position the lock block170is similarly urged to extend from the end of the astragal assembly150. Contact between the lock block170and the threshold22may cause shortening of the compression spring176. A bottom sealing pad178may be carried on the bottom of the lock block170and configured to help seal the lock block against the threshold22. An optional corner sealing pad180may also be provided on and carried with the lock block170for sealing against the stile of the active door panel14. In addition, an optional back sealing pad (not shown) may be provided on and carried with the lock block170on a face of the lock block opposite the corner sealing pad180. When provided, the back sealing pad helps seal between the lock block100and an edge of the passive door panel by residing in an opening in the astragal body.

FIG. 10shows the top end of the astragal assembly150. The bolt assembly30at the top end of the astragal assembly150is optionally provided with a guide block190. The guide block190includes a guide passage192through which the pin54is configured to slidably extend as the bolt50is actuated between the retracted and extended positions thereof. Unlike the lock block170used at the bottom end of the astragal body152, the guide block190is configured to be fixed within the channel158. Therefore, the guide block190guides and stabilizes the pin54, but does not extend from the top end of the astragal body152. The guide block190will generally not include compression spring176or the sealing pads178,180used with the lock block170. Therefore use of the guide block190may reduce assembly time and component costs relative to using a lock block170on both the top and bottom of the astragal assembly150. Sealing requirements at the top of an entryway10are generally less critical than at the bottom because the top is less susceptible to penetration by wind-blown water. Therefore, the sealing benefits of the lock block170may be less necessary at the top of the astragal assembly150, therefore promoting use of the guide block190.

As seen inFIG. 11, one or more trim covers194may be mounted to the astragal body to at least partially enclose the channel. The trim cover194may be provided with a slot196for providing access to the user interface72of the bolt assembly. The trim cover194may include a hole198for providing access to the actuation button102of the bolt assembly30.

Although the above disclosure has been presented in the context of exemplary embodiments, it is to be understood that modifications and variations may be utilized without departing from the spirit and scope of the invention, as those skilled in the art will readily understand. Such modifications and variations are considered to be within the purview and scope of the appended claims and their equivalents.