Lever operated door lock assembly

Abstract: A lever door lockset (20) includes an exterior subassembly (21) and an interior subassembly (55). Interior subassembly (55) includes a lever (56) positioned on an insert (62) which supports a rose insert (64). A half-round spindle (78) and a round spindle (80) are positioned through a spring biasing arrangement including spring (76) and through a bearing (88) supported by a shield (86). Shield (86) is assembled with rose insert (64). Exterior subassembly (21) includes a lever (22) which is assembled with an insert (24). A rose insert (32), a spring biasing arrangement including spring (40) and a cover (48) are mounted in assembly on insert (24). A latch assembly (94) including latch bolt (96) is coupled through half-round spindle (78) to levers (22) and (56) for movement of bolt (96) upon movement of the levers.

Description: The present invention relates to a lever operated door lock assembly, in particular to a lever operated assembly which allows for the changing of the hand of the related door with continued use of the existing levers. In some currently available lever operated lock assemblies (for ex. US-A-5 125 696), the lever is constructed for direct assembly with elements within the lock assembly for subsequent operation of an associated bolt operating mechanism and bolt. By use of such levers, each lever has to be designed for a dedicated function. For example, the lever is designed to function as an interior lever or an exterior lever. Also, the lever is designed to function with a left hand door or a right hand door. For example, a left hand door is a door which is hinged on the left side as viewed from the exterior thereof. Thus, several options must be considered when designing a lever for direct assembly with the lock assembly. Further, due to the above-noted requirement for different lever designs, multiple manufacturing facilities, warehouse storage facilities and retail counter space will be required thereby resulting in an overall lever-supply program which is costly and burdensome. Thus, there is a need for a lever for use with a door lock assembly which will overcome the problems encountered with currently available levers as noted above. It is an object of the present invention to provide a lever operated door lock assembly which is versatile in design for assembly at any typical location on a door. It is a further object of the present invention to provide a lever of common design which can be used at any typical location on a door and thereby reduces or substantially obviates the costly and burdensome efforts required for multiple designs of levers, each for a dedicated function. The present invention provides a door lock assembly characterised in that it comprises a pair of mirrored imaged levers each including a horizontal handle portion and a hub portion having a through bore extending therethrough and having a bottom portion and a set screw receiving hole extending vertically upwardly through the bottom portion to the through bore, and a latch assembly including an exterior cylindrical lever insert(24) having an end portion for insertion into the through bore (100) of one of the levers, an interior cylindrical lever insert having an end portion for insertion into the through bore of the other of the levers, emergency plug means secured to the exterior cylindrical lever insert, the hub portion through bore of each lever and each of the cylindrical lever inserts including cooperating means for preventing relative rotation between a lever and the cylindrical lever insert inserted into the through bore of the lever, and a pair of diametrically, vertically opposed set screw receiving holes in each of the cylindrical lever inserts selectively located so that when one of the cylindrical lever inserts is inserted into either of the lever hub portion through bores the pair of opposed cylindrical lever insert set screw receiving holes will be in vertical alignment with the set screw receiving hole (104) of the lever, so that the pair of levers can be secured to the cylindrical lever inserts with the lever set screw receiving hole at the bottom of the lever when the door is either a left hand door or a right hand door. An embodiment of a door lock assembly according to the present invention will now be described with reference to the accompanying drawings, in which: Figures 1 and 2 are exploded views which, when combined, illustrate elements of a lock assembly; Figure 3 is a sectional view of an exterior subassembly of the lock assembly of Figure 1; Figure 4 is a sectional view of an interior subassembly of the lock assembly of Figure 1; Figure 5 is a sectional view of a portion of a lever of the lock assembly of Figure 1; Figure 6 is an end view of a first insert which supports a lever of the exterior subassembly of Figure 3 for movement with the insert at an exterior portion of the subassembly and also supports interior portions of the subassembly; Figure 7 is a side view of the insert of Figure 6; Figure 8 is a sectional view, taken along line 8-8 of Figure 6, of the insert of Figure 6; Figure 9 is a sectional view, taken along line 9-9 of Figure 8, of the insert of Figure 6; Figure 10 is a sectional view, taken along line 10-10 of Figure 8, of the insert of Figure 6; Figure 11 is a side view, with parts broken away, of a second insert which supports a lever of the interior subassembly of Figure 4 for movement with the insert at an exterior portion of the subassembly and also supports interior portions of the subassembly; Figure 12 is a sectional view, taken along line 12-12 of Figure 11, showing the second insert; Figure 13 is a sectional view taken along line 13-13 of Figure 11 showing a portion of the second insert; and Figure 14 is a sectional view of an emergency plug of the lock assembly of Figure 1. Figures 1 and 2 illustrate collectively an exploded view of a lock assembly such as lockset (20). To illustrate the complete exploded view of lockset (20), Figures 1 and 2 are to be linked at centreline arrowheads "A" of each figure. As shown in Figure 1, an exterior lever subassembly (21) includes a lever (22) which is formed with a hub (23) and an integral handle (25) and which is positioned for assembly with a lever insert (24) and an emergency plug (26) and cover (28). A cap (30) is to be assembled temporarily with lever (22) and insert (24) until a set screw (not shown) is assembled with the lever and insert to facilitate attachment thereof. A rose insert (32) and cover (34) are positionable over an adjacent end (35) of insert (24) and held there by retaining ring (36). A washer (38), torque spring (40), stop plate (42) and housing (44) are also assembled on the adjacent end (35) of insert (24) and held there by retaining ring (46). A cover (48) is further placed on end (35) and held there by retaining ring (50). Screws (52) are inserted through aligned openings of the rose insert (32) and cover (34) and further through openings in cover (48) and are held there by a pair of screw retainers (54) which completes assembly (21). As shown in Figure 2, an interior lever subassembly (55) includes a lever (56) which is formed with a hub (57) and an integral handle (59) and which is positioned to receive a turnbutton insert (58) with a cover (60). The lever (56) is positionable onto a lever insert (62). A rose insert (64) and cover (66) are positioned on the inboard end of insert (62) and held there by retaining ring (68). A locking housing (70) supports a locking slide (72), a detent slide (74) and a detent torque spring (76). A half-round spindle (78) is nested partially around a round spindle (80) and both spindles are inserted through an axial opening of housing (70). Turnbutton insert (58) is formed with a square shank (82) which is inserted into a square hole (84) of round spindle (80). The turnbutton insert (58) can be rotated to rotate the round spindle (80). This results in adjustment of the components within the housing (70) to, in effect, lock the lockset (20) and preclude it from being operated by either lever (22) or lever (56). For example, a cam surface (not shown) on round spindle (80) is moved when turnbutton insert (58) is rotated to engage a ramp surface (85) on slide (72) to move the slide so that a notch (87) thereof is positioned about a base of an adjacent one of a pair of threaded posts (89). This prevents movement of either of levers (22) and (56) effectively to lock lockset (20). A security shield (86) has a central opening which supports a bearing (88) for limited rotation therein. The shield (86) is positioned against the inside of rose insert (64) with the half-round spindle (78) and round spindle (80) located through an opening (91) in the bearing (88) to complete the assembly (55). The round spindle (80) is free to rotate relative to the bearing (88). The half-round spindle (78) rotates the bearing (88) within its mount on the shield 86 to the limits allowed by interfering structure on the bearing and shield. This limited movement of the bearing (88) establishes the limits of rotation of the half-round spindle (78). As shown in Figures 1 and 2, the half-round spindle (78) passes through an opening (90) formed in a stationary frame (92) of a latch assembly (94) and facilitates retracting movement of a bolt (96) of the assembly. In particular, the bolt (96) is mounted within a case (93) and is spring-biased outwardly as shown in Figure 1. A slide (95) is mounted slidably within the frame (92). When the half-round spindle (78) is rotated, the slide (93) is moved in a direction away from the case (91) resulting in movement of a latch cam (not shown) within the case. The latch cam moves a pair of followers (not shown) to move a bolt extender (not shown), all within the case (91), thereby to retract the bolt (96). The rose insert (64) is formed with the pair of internally threaded posts (89) to receive the screws (52) to draw and hold the lever lockset (20) in assembly with the door (not shown). Figure 3 is an assembly view of the exterior lever assembly (21) and Figure 4 is an assembly view of the interior lever assembly (55). Initially, the exterior lever assembly (21) (excluding the lever (22), the interior lever assembly (55) (excluding the lever) (56) and the latch assembly (94) are assembled with the door. As shown in Figures 1 and 5, the lever (22) is formed with an opening (100) having diametrically opposed grooves (102) formed therein. Also, the lever (22) is formed with a lateral through hole (104) to facilitate initial assembly of the cap (30) and, later, of the set screw as noted above. Further, the opening (100) is formed with a prescribed diameter in a portion (103) including the grooves (102) and a slightly smaller diameter than the prescribed diameter in a remaining portion (105) of the hole. As shown in Figures 1 and 6 to 10, the exterior lever insert (24) is formed with a central cylindrical portion (106) and an outer cylindrical portion (108) of a diameter slightly less than the diameter of the central cylindrical portion. A pair of lugs (110) are formed in diametrically opposite locations on the periphery of the central cylindrical portion (106) and blend integrally with an annular flange (112) formed at the inner end of the central cylindrical portion. The flange (112) is formed with a diameter greater than the diameter of central cylindrical portion (106). The lever (22) is moved so that the opening (100) thereof is positioned over the cylindrical portions (106) and (108) of the insert (24). The lugs (110) are guided into the grooves (102) to orient the lever (22) properly with respect to the insert (24). Eventually, the flange (112) engages a face (114) (Figure 1) of the lever (22) to prevent further movement of the lever (22) onto the insert (24). It is noted that the stepped diameters of the portions (106) and (108) of the insert (24) fit frictionally into the complementary stepped diameters of the portions (103) and (105), respectively, of the hole (100) of the lever (22). As insert (24) is seated in the hold (100) of the lever (22), the lever hole (104) is automatically aligned with one of two set screw receptacles (116) formed on diametrically opposite sides of the outer cylindrical portion (108). In view of the symmetry of the insert (24), either receptacle (116) may be aligned with the lever hole (104). As shown in Figures 1, 7, 8, and 9, an inboard cylindrical portion (118) of the insert (24) is formed with three axially spaced annular grooves (120) for receipt of the retaining rings (36, 46, and 50) as described above. The insert (24) is formed with an axial hole (122) for receipt of one end of the half-round spindle (78) (Figure 2). As shown in Figures 6, 8, and 10, a pair of diametrically spaced rails (124) are formed in the axial direction within the hole (122) of the insert (24) and provide shoulders (126) (Figure 10) for engagement with the outer edges (128) (Figure 2) of the half-round spindle (78). In this manner, when the lever (22) is rotated, one of the shoulders (126) will engage an adjacent one of the edges (128) to move the half-round spindle (78) and thereby retract the bolt (96) of the latch assembly (94). As viewed in Figure 1, a pair of spaced tabs (132) extend inwardly from an inner face of the rose insert (32) and are located to engage the extended ends (134) of the spring (40). In assembly, a pair of axially directed tabs (136) of the housing (44) extend through and past the stop plate (42) and into position adjacent the ends (134) of the spring (40). The housing (44) is also formed with a pair of radially projecting lugs (138) which are located within a pair of diametrically opposed, axially directed slots (140) (Figures 1, 7, and 8) formed in an inner end of the insert (24). As the lever (22) is operated, the insert (24) is rotated and, through the lugs (138), drives or rotates the housing (44). One of the tabs (136) engages an adjacent one of the ends (134) at the extreme ends of a slot (139) or arcuate surface (141) of the spring (40). Upon continued operation of the lever (22), the spring (40) is tensioned. Eventually, the tabs (136) engage stop surfaces of the stop plate (42) which limits the travel of the housing (44) and the lever (22). Upon release of the lever (22), the tensioned spring (40) will facilitate return of the lever to its home position. As shown in Figure 2, the lever (56) is a mirror image of the lever (22) (Figure 1) and is internally structured in a similar fashion. Further, as shown in Figures 11, 12 and 13, the lever insert (62) is similar in structure to the lever insert (24) (Figure 1) except that the insert (62) is shorter and has only a single annular groove (142) for receipt of the single retaining ring (68). Also, the insert (62) is formed with a through hole (144) in a central cylindrical portion (146) thereof for receipt of a tab on the spindle (78) in the event that such a tab is to be used. The lever insert (62) is further formed with an outboard cylindrical portion (148) of slightly less diameter than the diameter of cylindrical portion (146). Also, the insert (62) is formed with a short inboard cylindrical portion (150) in which is formed the groove (142). A pair of diametrically spaced lugs (152) and an annular flange (154) are formed on the periphery of the central portion (146) at the inboard end thereof. The insert (62) is formed with an axial opening (156) which is formed with a pair of diametrically spaced rails (158) (Figure 12) having shoulders (160). Further, the insert (62) is formed with a pair of diametrically opposed set screw receptacles (162). The functions of these elements correspond to the functions of the similar elements associated with the lever (22) and described above. It is noted that the dimensional and configurational character of the insert (62) as viewed from flange (154) to the outboard end of the insert (62) is the same as that of the insert (24) as viewed from the flange (112) to the outboard end of the insert (24). Thus, each of the inserts (24) and 62) presents the same assembly configuration to the levers (22) and 56). As shown in Figures 8 and 9, the insert (24) is formed at its outer end with an axial opening (164). The opening (164) is formed by a countersunk portion (166), a radially inwardly-projecting rib (168) and a hole (170) of a diameter larger than the diameter of facing portions of the rib. In this fashion, the rib (168) forms a circular fence within the opening (164). In similar fashion, a rib (171) is formed in the insert (62) (as shown in Figure 13). As shown in Figures 1 and 14, the emergency plug (26) is formed with an axial opening (172) which extends through a cap (174) and a stem (176) thereof. A locking element (178) is attached or formed to the free end of the stem (176). The element (178) includes a plurality of flexible locking tabs (180) which are flared radially outwardly from the free end of stem (176) toward the cap (174). The cover (28) is shown in assembly with the cap (174) of the emergency plug (26). When assembling the plug (26) with the insert (24), the stem (176) is inserted into the opening (164) whereby the tabs (180) engage the rib (168) and are flexed radially inwardly thereby. Eventually, the tabs (180) clear the rib (168) and return to the position illustrated in Figure 14 whereby the tabs and the rib retain the plug (26) with the insert (24) as shown in Figure 3. The hole (172) provides probing access to an end (181) (Figure 4) of the round spindle (80). By using the arrangement with the emergency plug (26), the lever (22) can be designed generically for all types of intended use of a given hand (left or right) instead of requiring many specific types of levers each designed for a single dedicated use. It is noted that the insert (62) for use with the lever (56) is also formed identical to the insert (24). Thus, the insert (62 receives and retains a head (182) (Figure 2) of the turnbutton insert (58) in the same manner that the insert (24) receives and retains the emergency plug (26). Referring to Figures 2, and 4, the half-round spindle (78) is positioned through a complementary shaped portion of a hole (182) formed through the housing (70). As the lever (56) is operated, the half-round spindle (78) is rotated to cause rotation of the housing (70). As the housing (70) is rotated, one or the other of the ends (134) of the spring (40) are moved by engaging structure of the housing, whereby the spring is tensioned. Upon release of the lever (56), the tensioned spring (40) will facilitate return of the lever to its home position. Referring further to Figures 2 and 4, the bearing (88) is formed with a round hub (184) through which is formed the opening (91). Also, the bearing (88) is formed with a round flange (186) of diameter greater than the diameter of the hub (184). A pair of lugs (188) extend radially outwardly from the hub (184) and adjacent a side wall of the flange (186). The hub (184) is positioned within an opening (190) of the shield (86) for rotation between spaced curved surfaces (192) of the shield. The lugs (188) are thereby positioned to engage selected ones of a plurality of stop surfaces (194) also located in the opening (190). The bearing (88) is frictionally positioned onto and over the half-round spindle (78) with the flange (186) being pressed against adjacent portions of the shield (86) to hold the shield in place within the interior lever subassembly (55). The shield (86) is further formed with a pair of spaced curved deflectors (196) which shields the bolt operating mechanism from external tampering, for example, by placement of a probe through the hole (not shown) formed normally in the door for receipt of the lockset (20). Also, the deflectors (196) fit into the opening formed in the door for receipt of the lockset (20) and preclude radially lateral movement of the shield (86). The shield (86) is also formed with a flange (198) which fits into an overhanging rim (200) of the rose insert (64) as shown in Figure 4. This precludes radially lateral movement of the shield (86) and the rose insert (64 relative to each other. An opening (202) formed in the rose insert (64) is positioned about the inboard cylindrical portion (150) of the lever insert (62) and serves as a first bearing support for the interior lever assembly (55). Likewise, the shield, (86) together with the bearing (88), which is positioned about the half-round spindle (78), serve as a second bearing support for the interior lever subassembly (55) which is spaced inboard of the first bearing support. As viewed in Figures 1 and 3, the rose insert (32) is formed with an opening (204) which is positioned on the lever insert (24) as noted above and provides a first bearing support for the exterior lever subassembly (21). The cover (48) is formed with an opening (206) which is also positioned on the lever insert (24) at a location spaced from the opening (204) of the rose insert (32) and which serves as a second bearing support for the exterior lever subassembly (21). The cover (48) is formed with a flange (208) which fits radially inwardly of an overhanging rim (210) of the rose insert (32) to preclude radially lateral movement of the rose insert (32) and the cover (48) relative to each other. Also, the cover (48) is formed with a hub (212) which extends in an axial inboard direction. The hub (212) fits into the opening formed in the door for receipt of the lockset (20) and precludes radially lateral movement of the cover (48). Referring now to the exploded view as illustrated in Figures 1 and 2, the exterior lever (22) and the interior lever (56) are arranged for a left hand door, that is, a door which is hinged on the left when viewed from the exterior of the door. In this arrangement, the handle portion of each of the levers (22) and (56) extend toward the hinged side of the door. Assume that one desires to change the hand of the door to a right hand. When changing a door from one hand to the other, e.g. left to right, the exterior and interior sides of the door remain unchanged. However, the latch assembly (94) is moved from one vertical edge of the door to the other vertical edge. Thus, the lever lockset (20) must be moved accordingly. Even so, it would appear that the exterior side lever insert (24) would remain on the exterior side of the door and the interior lever insert (62) would remain on the interior side of the door. As noted, the handle portion of levers (22) and (56) extend toward the hinged side of the door. Therefore, when changing the hand of the door, the levers (22) and (56) must be removed from their respective inserts (24) and (62) and rotated one hundred and eighty degrees to accommodate the hand change. However, when this is done, the hole (104 of each lever (22) and (56) will be facing upwards for receipt of a set screw. Aesthetically, this is unacceptable. To rectify this situation, and since levers (22) and (56) are the mirror images of each other, the lever (56) can now be used for assembly with the exterior lever insert (24) and the lever (22) can now be used for assembly with the interior lever insert (62). In both instances, the lever hole (104) will be located on the underside of the respective levers (22) or (56) and the handle portions will extend toward the hinged side of the door. This demonstrates one of the versatile advantages of the generic hand design of the levers of this invention. It is to be understood that the illustrated and above-described lever lockset (20) is of the privacy type. Other types, such as a passage type, use similar construction as the privacy type without departing from scope of the invention. For example, in a passage type lever lockset, a passage lever, would not be formed with an outboard opening such as the opening (100) of the lever (22). Instead, the outboard surface of the lever in the area occupied by the opening (100) would be covered and integral with the surface areas which are normally contiguous with the opening. Further, in still other types of locksets, such as, for example, an entry or vestibule type, an exterior type lever, such as lever (22), and mating insert, such as the insert (24), are used on an interior side of the door and a knob operator with a cylinder lock is used on the exterior side of the door. In the vestibule type, the lever has a dedicated half-round spindle and return spring which operates independently of operation of the knob. Use of the generic lever (22) or (56) in combination with the exterior type insert (24) in an entry or vestibule lockset does so without departing from scope of this invention.

Claims: A door lock assembly (20) which comprises: a pair of mirrored imaged levers (22,56) each including a horizontal handle portion (25,59) and a hub portion (23,57) having a through bore (100) extending therethrough and having a bottom portion and a set screw receiving hole (104) extending vertically upwardly through the bottom portion to the through bore (100), and a latch assembly (94) including an exterior cylindrical lever insert(24) having an end portion (108) for insertion into the through bore (100) of one of the levers (22,56), an interior cylindrical lever insert (62) having an end portion (148) for insertion into the through bore (100) of the other of the levers (22,56), emergency plug means (26) secured to the exterior cylindrical lever insert (24), the hub portion through bore (100) of each lever (22,56) and each of the cylindrical lever inserts (24,62) including cooperating means for preventing relative rotation between a lever (22,56) and the cylindrical lever insert (24,62) inserted into the through bore (100) of the lever (22,56), and a pair of diametrically, vertically opposed set screw receiving holes (116,162) in each of the cylindrical lever inserts (24,62) selectively located so that when one of the cylindrical lever inserts (24,62) is inserted into either of the lever hub portion through bores (100) the pair of opposed cylindrical lever insert set screw receiving holes (116,162) will be in vertical alignment with the set screw receiving hole (104) of the lever (22,56), so that the pair of levers (22,56) can be secured to the cylindrical lever inserts (24,62) with the lever set screw receiving hole (104) at the bottom of the lever (22,56) when the door is either a left hand door or a right hand door. A door lock assembly according to claim 1 characterised in that it comprises means for preventing the operation of the latch assembly ((94) including turn button means (58) secured to the interior cylindrical lever insert (62). A door lock assembly according to claim 2 characterised in that the turn button means (58) comprises a turn button insert (58) and a turn button insert cover (60). A door lock assembly according to any of claims 1 to 3 characterised in that the emergency plug means (26) comprises an emergency plug (26) and an emergency plug cover (28).

Inventors: GHOSTLEY THOMAS J, GHOSTLEY, THOMAS J.
Applicants: EMHART INC, EMHART INC.
Application year: 1993
Main classification: E05B3
IPC codes: E05B63, E05C1, E05B3, E05B65