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FIELD 
       [0001]    The present invention relates to a shoot bolt assembly for use in a folding panel system. 
       BACKGROUND 
       [0002]    A known folding panel system includes folding panels to close an interior from an exterior of, say, a house or building. The panels are supported by a series of pivot sets and rollers between an overhead track and an elongate channel that extends beneath the panels. The elongate channel is defined by an extruded profile that forms a sill of the system. 
         [0003]    The panels include an intermediate panel that is coupled to an adjacent pivot panel by a set of hinges. A shoot bolt assembly is used to lock the intermediate panel in a closed condition, where top and bottom edges of the intermediate panel are secured relative to keepers that are in fixed positions with respect to the guide track and channel. 
         [0004]    The shoot bolt assembly is mounted into a side edge of the intermediate panel and includes two shoot bolts coupled to a lock body by elongate rods. The rods, lock body and shoot bolts are recessed into a groove that is machined into the side edge of the panel. The shoot bolts are housed in inserts that are screwed into opposite ends of the groove. The rods are housed internally of cover strips that extend along the edge of the panel, either side of the lock body. 
         [0005]    An actuating handle and a lock barrel couple to the lock body from an interior face of the panel. The set of hinges have hinge knuckles that are also positioned adjacent the interior face of the panel. 
         [0006]    Screws are used to attach the hinges to the intermediate panel, through the cover strips and into the back of the groove. Careful positioning of the hinges over the cover strips is required to avoid fouling operation of the rods. 
         [0007]    The exterior surface of the panel is used as a datum point to calculate the relative position of the groove and lock body in the side edge of the panel. If a different width panel is used, the position of the groove and lock body with respect to the exterior surface will remain the same but different components such as a handle, lock barrel and hinges will be needed since all those components arc mounted relative to the interior surface. 
       OBJECT 
       [0008]    The present invention seeks to provide an alternative shoot bolt assembly, folding panel system and/or method of construction. 
       SUMMARY 
       [0009]    In accordance with the invention, there is provided a shoot bolt assembly for mounting in a groove formed, in a side edge of a panel, the assembly including a handle mechanism, a shoot bolt and a rod to connect the handle mechanism to the shoot bolt so that actuation of the handle mechanism causes the shoot, bolt to extend and retract from a top or bottom edge of the panel, wherein the assembly includes a hinge block arranged to fit in the groove, the hinge block having a deck with attachment holes for a hinge and fixing platforms that secure the block to a base of the groove, wherein a passage is provided beneath the deck and platforms for the rod to pass through. 
         [0010]    Preferably, the block includes side supports that distance the deck from the platforms. 
         [0011]    Preferably, the platforms bridge between the side supports and extend from either end of the deck, to receive a respective fastener to fix the platforms to the base of the groove. 
         [0012]    Alternatively, the platforms are located between the ends of the block and the deck has openings to allow access to the platforms, in order for the platforms to receive associated fasteners for fixing the block to the has of the groove. 
         [0013]    Preferably, the assembly further includes clips that are fastened into the groove either side of the block to ensure alignment of the rod is maintained through the groove. 
         [0014]    Preferably, the clips include resilient fingers to hold a cover strip. 
         [0015]    Preferably, the assembly further includes multiple blocks arranged along the groove at locations where hinges are positioned to connect the panel to an adjacent pivot panel. 
         [0016]    Preferably, the assembly further includes a second shoot bolt and an associated rod for attachment to the handle mechanism such that operation of the handle mechanism causes the first and second shoot bolts to simultaneously extend and retract from the respective top and bottom edges of the panel. 
         [0017]    In another aspect, there is provided a hinge block for the shoot bolt assembly, as described above, including a deck with attachment holes for a hinge and fixing platforms to mount the block in a groove in a side edge of a panel, with the deck in spaced relation from a base of the groove so as to define a passage beneath the deck. 
         [0018]    Preferably, the platforms bridge between side supports of the block and extend from either end of the deck, each platform having an aperture to receive a fastener to secure the block in the groove. 
         [0019]    Alternatively, the platforms are located between ends of the block and the deck has openings to allow access to the platforms, in order for the platforms to receive associated fasteners for fixing the block to the base of the groove. 
         [0020]    Preferably, the block includes shoulders that project above a level of the dock in order to locate a hinge over the attachment holes. 
         [0021]    A folding panel system including a series of panels mounted between an overhead track and a sill, wherein two of the panels are hinged together and the shoot bolt assembly, as described above, is mounted in a side edge of one of the panels. 
         [0022]    In another aspect, there is provided a method of constructing a panel with a grooved formed in a side edge of the panel and a shoot bolt assembly, as described above, mounted in the groove including: 
         [0023]    mounting the handle mechanism in a rebate formed in rebase of the groove; 
         [0024]    fixing the hinge block in the groove so the deck is substantially level with the side edge; 
         [0025]    inserting a rod through the passage beneath the deck; 
         [0026]    attaching ends of the rod to the handle mechanism and the shoot bolt. 
         [0027]    Preferably, the method further includes attaching a hinge to the hinge block by screwing fasteners into the deck. 
         [0028]    Preferably, multiple hinge blocks are fixed along the groove, at locations where hinges are positioned to connect the panel to an adjacent panel. 
         [0029]    Preferably, the method further includes inserting a second rod in the channel, from an opposite side of the handle mechanism, passing the second rod through one or more of the multiple hinge blocks and attaching ends of the second rod to the handle mechanism and a second shoot bolt. 
         [0030]    Preferably, clips are fixed into the groove, either side of the cleats in order to maintain alignment of the rods in the groove. 
         [0031]    Preferably, cover strips are fitted over the groove and held in place by resilient fingers of the clips. 
         [0032]    Preferably, an interior face of the panel is used as a datum point for determining the relative position of the shoot bolt assembly. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0033]    The invention is more fully described, by way of non-limiting example only, with reference to the accompanying drawings, in which: 
           [0034]      FIG. 1  is an exploded perspective view of a shoot bolt assembly mounted in an edge of a panel; 
           [0035]      FIG. 2  is a perspective view showing a handle mechanism being inserted in the edge of the panel; 
           [0036]      FIG. 3  is a perspective view showing hinge blocks being inserted in the edge of the panel; 
           [0037]      FIG. 3A  illustrates another example of a hinge block; 
           [0038]      FIG. 4  is a perspective view of a series of clips being mounted in the edge of the panel; 
           [0039]      FIG. 5  is a perspective view of end cleats being introduced into the panel; 
           [0040]      FIG. 6  is a perspective view of rods being fitted into the panel; 
           [0041]      FIG. 7  illustrates the rods being connected to shoot bolts of the assembly; 
           [0042]      FIG. 8  illustrates a handle and lock barrel being connected to the handle mechanism; 
           [0043]      FIG. 9  is a perspective view of cover strips fitted over the edge of the panel; 
           [0044]      FIG. 10  is a perspective view showing hinges being mounted to the hinge blocks; 
           [0045]      FIG. 11 a    is a top view of the panel and shoot bolt assembly with a non-mortise hinge; 
           [0046]      FIG. 11 b    is a side view of the non-mortise hinge mounted to the panel; 
           [0047]      FIG. 11 c    is a cross sectional view, along the line A-A shown in  FIG. 11   b;    
           [0048]      FIG. 12 a    is a top view of the panel and shoot bolt assembly with a mortise hinge; 
           [0049]      FIG. 11 b    is a side view of the mortise hinge mounted to the panel; 
           [0050]      FIG. 12 c    is a cross-sectional view, along the line B-B shown in  FIG. 12   b;    
           [0051]      FIG. 13 a    is a view of an interior side of a panel system; 
           [0052]      FIG. 13 b    is an end view of the system; 
           [0053]      FIG. 13 c    is an enlarged section C, shown in  FIG. 13   b;    
           [0054]      FIG. 13 d    is an enlarged section D, shown in  FIG. 13   b;    
           [0055]      FIG. 14 a    is view similar to  FIG. 13 c   , with a panel of increased thickness; 
           [0056]      FIG. 14 b    is a view similar to  FIG. 13 d   , showing the panel of increased thickness; 
           [0057]      FIG. 15 a    is a view similar to  FIG. 14 a   , showing a panel of greater thickness; and 
           [0058]      FIG. 15 b    is a view similar to  FIG. 14   b,  showing the panel of greater thickness. 
       
    
    
     DETAILED DESCRIPTION 
       [0059]    Throughout the following description, like references will be used to denote, like parts. 
         [0060]      FIG. 1  shows a shoot bolt assembly  1  arranged to be mounted in a groove  2  formed in a side edge  3  of a folding door panel  4 . 
         [0061]    The assembly  1  includes a handle mechanism  5  that has a body  6  and linkages  7  that move in and out of the body  6  under action of a handle  8 , to drive shoot bolts  9  in and out of respective end cleats  10 . The shoot bolts  9  are connected to the linkages  7  via elongate rods  11  that are attached to the respective linkage  7  and shoot bolt  9  via connectors  12 . 
         [0062]    Hinge blocks  13  are arranged intermediate the body  6  and the shoot bolts  9 . The hinge blocks  13  include locating holes  14  for hinges  15  to attach to. 
         [0063]    A series of guide clips  16  are provided along the length of the groove  2  to maintain alignment of the rods  11 . 
         [0064]    Cover strips  17  are arranged to extend between the blocks  13  and a further cover strip  17  is fitted over the handle mechanism  5 . The cover strips  17  are held in place by the clips  16 . 
         [0065]      FIG. 2  illustrates a first step of constructing and installing the assembly  1  in the groove  2 , where the handle mechanism  5  is introduced into a rebate  58  formed in a base  18  of the groove  2  so that a rotary coupling  59  aligns with a first aperture  19  and an opening  20  in the body  6  aligns with a second aperture  21 . 
         [0066]    The length of the rebate  58  is sufficient to accommodate movement of the linkages  7  in and out of the body  6  in a direction indicated by arrow  22 . The linkages  7  include an elbow joint  23  and a socket  24 . Movement of the linkages  7  in and out of the body  6  results in corresponding movement of the sockets  24  lengthwise of the groove  2 . 
         [0067]      FIG. 3  shows the blocks  13  being fastened in the groove  2 . Each block  13  includes an elevated deck  25  with attachment holes  26  and supporting platforms  27  that extend from either end  28  and are secured to the base  18  of the groove  2  with fasteners  29 . The platforms  27  extend between side supports  30  and provide a seat  32  for the associated fastener  29 . The platforms  27  are in spaced relation to the deck  25 , in a direction of extent of the block  13 , to allow clear access from a deck side  31  of the block  13  to screw the fastener  29  into the associated platform and the underlying base  18  of the groove  2 . 
         [0068]    The side supports  30  distance the deck  25  from the base  18  and define a passage  33  that extends the length of the block  13 , beneath the underside  34  of the deck  25  and the platforms  27 . When positioned in the groove  2 , the deck  25  of each block  13  is substantially level with the side edge  3  of the panel  4 . 
         [0069]    An alternative form of hinge block  13  is shown in  FIG. 3A  where like parts are denoted with like reference numerals. A passage  33  again extends through the block  13  between the deck  25  and platforms  27 , however, instead of projecting from ends  28  of the deck  25 , the platforms  27  are instead located internally of the block  13 , beneath the deck  25 . Openings  83  are provided in the deck  25  to allow access to the platforms  27  so that fasteners (not shown) can he screwed into seats  32  provided in each platform  27 , directly through the block  13  from a deck side  31  of the block  13 . The block  13  also includes shoulders  84  that project above the level of the deck  25  to assist in locating the hinge over the attachment holes  26 . 
         [0070]      FIG. 4  illustrates the clips  16  being introduced into the groove  2 . Each clip  16  is generally U-shaped with resilient fingers  35  and a fastening screw  36  to locate the clip  16  either side of an associated block  13 . As mentioned above with reference to  FIG. 1 , the clips  16  serve a dual role of guiding the rods  11  while holding the cover strips  17 . The resilient fingers  35  serve to hold the cover strips  17  in place. 
         [0071]      FIG. 5  shows the end cleats  10  being positioned in the ends  37  of the groove  2 . Each cleat  10  includes through holes  38  for attaching the cleats  10  in the groove  2 . The cleats  10  house the respective shoot bolts  9  that are arranged to slide lengthwise of the cleats  10 . A socket  39  is connected to each shoot bolt  9 . 
         [0072]      FIG. 6  shows installation of the rods  11  which are initially measured and cut to length. Prior to installation, the rods  11  are inserted in a drilling jig  40  whom a template  41  allows holes  42  to be drilled in either end  43  of the rods  11  so that each hole  42  is oriented in the same direction. 
         [0073]      FIG. 7  shows the rods  11  being inserted in the sockets  39  of the shoot bolts  9  so that the holes  42  in the rods  11  align with holes  43  provide in the sockets  39  in order for the connectors  12  to lock the rods  11  and sockets  39  together. When the rods  11  are inserted through each of the clips  16  and passages  33  of the blocks  13 , a similar retainer connector  12  allows the rods  11  and sockets  24  of the linkages  7  to be connected. 
         [0074]      FIG. 7  also shows fasteners  44  in the holes  38  to secure the shoot bolt cleats  10  in the groove  2 , once the rods  11  are connected. 
         [0075]      FIG. 8  shows the handle  8  and a cover plate  45  being mounted to the door panel  4 . The handle  8  has a shall  46  that extends through the first aperture  19 , to engage the rotary coupling  18 . A lock barrel  47  is loaded into the opening  20  in the body  6 , through the second aperture  21 , and the cover plate  45 . Two additional bolts  48  are provided to fix the handle mechanism  5  in the rebate  58 . A further bolt  85  fixes the lock barrel  47  in position. 
         [0076]      FIG. 9  shows the next step of assembly, where the cover strips  17  are snap fit onto the clips  16 , between the respective blocks  13  and the further strip  17  is attached over the handle mechanism  5 . 
         [0077]      FIG. 10  illustrates the last stage of constructing the assembly  1 , where the hinges  15  are attached to the blocks  13  using fasteners  49 . The hinges  15  have pre-determined mounting holes  50  that align with the attachment holes  26  of the blocks  13 . 
         [0078]      FIG. 11  shows a hinge  15  attached to one of the blocks  13 . The hinge  15  is a non-mortise hinge and includes a centre leaf  51  nested between two outer leaves  52 . Holes  50  in both the outer leaves  52  and the centre leaf  51  align with the attachment holes  26  in the deck  25  so that either the centre leaf  51  or outer leaves  52  can be attached to the hinge  15 , as required.  FIG. 11 c    shows a fastener  49  that is screwed into the block  13  so that the hinge  15  can be securely anchored to the deck  25 , while the passage  33  below the deck  25  remains clear for unobstructed movement of the rod  11  through the passage  33 . 
         [0079]    The interior face  53  of the panel  4  provides a datum point for the groove  2  and block  13 , which in turn dictates the positioning of the attachment holes  26  so that the hinge  15  is located with the knuckle  54  of the hinge  15  in close proximity to the face  53  of the panel  4 . 
         [0080]      FIG. 12  shows a mortise hinge  15  with two large overlapping hinge leaves  55 ,  56 . In this case, the interior face  53  of the panel  4  again provides a datum point for the knuckle  54  and positioning of the groove  2 . However, the hinge leaves  55 ,  56  are wider and have a height dimension due to their stacked orientation so a recess  57  needs to be formed in the edge  3  of the panel  4  and a block  13 , as described with reference to  FIG. 3A , is used with a different configuration of attachment holes  26 . In this case, the platforms  27  are internal of the block  13  and the raised shoulders  84  assist in locating the hinge  15  over the attachment holes  26 . 
         [0081]      FIG. 13  shows an interior view of a folding panel system  60  with a series of panels  61  arranged between an overhead track  62  and a sill  63 . The panels  61  include a pivot panel  64 , an intermediate panel  65 , an inactive/end panel  66  and an active access panel  67 . Pivot sets  68  mount the pivot panel  64  and the active panel  67  in the track  62  and a wheeled hanger  69  supports the intermediate and inactive/end panel  65 ,  66 . 
         [0082]    The shoot bolt assembly  1  is mounted in the edge  3  of the intermediate panel  66  adjacent the pivot panel  64 . 
         [0083]    As indicated above, the interior face  53  of the panel  4  is used as a datum point for the assembly  1 . With reference to  FIGS. 13 c  and 13 d    in particular, this results in the shoot bolts  9  projecting from top and bottom edges  70 ,  71  of the panel  4  at a fixed distance from the interior face  53 , into respective keepers  72 ,  73  associated with the track  62  and sill  63 . The sill  63  is in the form of an extruded profile  74  that defines a channel  75  for a bottom pivot  76  of the end panel  66  and an adjacent slot  77  that functions as the keeper  73  for the shoot bolt  9 . 
         [0084]    If a thicker panel  78  is used, such as shown in  FIG. 14 , the position of the shoot bolts  9  relative to the face  53  of the panel  78  will remain the same and the distance between the shoot bolts  9  and the track  62  and associated channel  75  increases, which means the position of the keepers  72 ,  73  relative to the track  62  and the channel  75  will change.  FIG. 14 a    shows the increased distance between the keeper  72  and the track  62  while  FIG. 14 b    shows a second pre-formed slot  79  in the profile  74 , which is further from the channel  75 , functioning as the keeper  73 . As such, the same profile  74  is able to provide two differently positioned keepers  73  in order to accommodate the different width panel  78 . 
         [0085]      FIG. 15  shows another panel  80  of even greater width. In this case, the keepers  72 ,  73  for the top and bottom shoot bolts  9  are both separately mounted in a timber frame  81  adjacent the track  62  and sill  82 . 
         [0086]    It should be appreciated that since the interior face  53  of the panel  80  is used as the datum point for the assembly  1 , the position of the groove  2 , rods  11  and handle mechanism  5  within the panel  80  is the same, regardless of the width of the panel  80 . This means all of the components of the assembly can be universally applied to different width panels, including the handle  8 , lock barrel  47  and hinges  15 . The only change required for door panel system  60  if different width panels are used, is for the keepers  72 ,  73  to be moved relative to the track  62  and channel  75  and a different sill profile  74  or an independently mounted keeper  73  may be needed if the profile  74  is not already configured to provide optional keeper positions. 
         [0087]    As such, no changes are needed to the assembly  1  for use with different width panels. This is in marked contrast to the prior art where different hinges, handles and lock barrels would be needed. 
         [0088]    It may also be appreciated the hinge blocks  13  of the invention provide an advantage of the prior art technique of simply screwing hinges on to the cover strips as the blocks  13  provide attachment holes  26  in predefined positions that allow hinges  15  to be secured to the decks  25  of the blocks  13  without interfering with the rods  11  that pass through passages  33  beneath the decks  25 . This provides a considerable advantage compared to the prior art where operation of the rods could easily be fouled by fasteners being screwed into incorrect locations on the cover strips. Also, the hinge blocks  13  provide an additional function of reinforcing the edge  3  of the panel  4 , which provides greater structural rigidity and strength to the panel edge  3  to compensate for any structural weakness introduced as a result of machining the groove  2  in the panel  4 . 
       LIST OR PARTS 
       [0089]      1 . Shoot bolt assembly 
         [0090]      2 . Groove 
         [0091]      3 . Side edge 
         [0092]      4 . Panel 
         [0093]      5 . Handle mechanism 
         [0094]      6 . Body 
         [0095]      7 . Linkage 
         [0096]      8 . Handle 
         [0097]      9 . Shoot bolt 
         [0098]      10 . End cleat 
         [0099]      11 . Rod 
         [0100]      12 . Connector 
         [0101]      13 . Hinge block 
         [0102]      14 . Hole 
         [0103]      15 . Hinge 
         [0104]      16 . Clip 
         [0105]      17 . Cover strip 
         [0106]      18 . Rotary coupling 
         [0107]      19 . Aperture 
         [0108]      20 . Opening 
         [0109]      21 . Aperture 
         [0110]      22 . Arrow 
         [0111]      23 . Elbow joint 
         [0112]      24 . Socket 
         [0113]      25 . Deck 
         [0114]      26 . Hole 
         [0115]      27 . Platform 
         [0116]      28 . End 
         [0117]      29 . Fastener 
         [0118]      30 . Support 
         [0119]      31 . Deck side 
         [0120]      32 . Seat 
         [0121]      33 . Passage 
         [0122]      34 . Underside 
         [0123]      35 . Finger 
         [0124]      36 . Screw 
         [0125]      37 . End 
         [0126]      38 . Hole 
         [0127]      39 . Socket 
         [0128]      40 . Jig 
         [0129]      41 . Template 
         [0130]      42 . Hole 
         [0131]      43 . Hole 
         [0132]      44 . Fastener 
         [0133]      45 . Cover plate 
         [0134]      46 . Shaft 
         [0135]      47 . Lock barrel 
         [0136]      48 . Bolt 
         [0137]      49 . Fastener 
         [0138]      50 . Hole 
         [0139]      51 . Centre leaf 
         [0140]      52 . Outer leaves 
         [0141]      53 . Interior face 
         [0142]      54 . Knuckle 
         [0143]      55 . Hinge leaf 
         [0144]      56 . Hinge leaf 
         [0145]      57 . Recess 
         [0146]      58 . Rebate 
         [0147]      59 . Rotary coupling 
         [0148]      60 . Folding panel system 
         [0149]      61 . Panels 
         [0150]      62 . Track 
         [0151]      63 . Sill 
         [0152]      64 . Pivot panel 
         [0153]      65 . Intermediate panel 
         [0154]      66 . End panel 
         [0155]      67 . Active panel 
         [0156]      68 . Pivot sets 
         [0157]      69 . Hanger 
         [0158]      70 . Top edge 
         [0159]      71 . Bottom edge 
         [0160]      72 . Keeper 
         [0161]      73 . Keeper 
         [0162]      74 . Profile 
         [0163]      75 . Channel 
         [0164]      76 . Bottom pivot 
         [0165]      77 . Slot 
         [0166]      78 . Panel 
         [0167]      79 . Slot 
         [0168]      80 . Panel 
         [0169]      81 . Frame 
         [0170]      82 . Sill 
         [0171]      83 . Openings 
         [0172]      84 . Shoulders 
         [0173]      85 . Bolt

Summary:
The invention relates to a shoot boll assembly for mounting in a groove formed in a side edge of a panel, the assembly including a handle mechanism, a shoot bolt and a rod to connect the handle mechanism to the shoot bolt so that, actuation of the handle mechanism causes the shoot bolt to extend and retract from a top or bottom edge of the panel, wherein the assembly includes a hinge block arranged to fit in the groove, the hinge block having a deck with attachment holes for a hinge and fixing platforms that secure the block to a base of the groove, wherein a passage is provided beneath the deck and platforms for the rod to pass through. The invention also relates to a hinge block for the shoot bolt assembly, a folding panel system and a method of constructing a panel.