Abstract:
A door handle spring assembly is provided for biasing a catch releasably coupling a door handle to a sleeve. The spring assembly includes a first arm engaged with the catch, a second arm extending outwardly from the sleeve, and a loop portion formed between the first and second arms. The first arm and the loop portion are retained within the sleeve. The spring further functions to exert a radial biasing force between the handle and the sleeve to minimize play therebetween.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates to a door handle assembly and more particularly to a lockset mechanism for a door handle assembly.  
       BACKGROUND OF THE INVENTION  
       [0002]     Door handle assemblies typically include an internal locking mechanism which operates a bolt extending from a door into a door jamb. The locking mechanism and bolt are operably controlled by a pair of operator portions, usually levers or knobs. A sleeve supports the operator portions in a pair of mounting plates which are fixed to the door.  
         [0003]     The operator portions have a bore formed at one end sized to receive the sleeve. The sleeve typically includes a catch to releasably secure the operator portion. The catch is mounted within the sleeve and moves to engage the operator portion when the operator portion is slid onto the sleeve. A spring biases the catch to engage the operator portion to lock it to the sleeve, preventing removal of the operator portion without first disengaging the catch.  
         [0004]     While the above method of assembly easily allows the operator portion to be attached to the door handle assembly, often there can be play between the operator portion and the sleeve. This play is, in part, due to the necessary draft between the bore of the operator portion and the sleeve that allows the operator portion to receive the sleeve. This play is undesirable since it may be associated with poor quality and workmanship.  
         [0005]     Therefore, it is an object of the present invention to provide the art with an improved sleeve and spring design that operates a catch while also eliminating the play between the sleeve and an attached operator portion.  
       SUMMARY OF THE INVENTION  
       [0006]     A door handle assembly is provided which includes a sleeve having a transverse slot extending into the sleeve and a catch mounted in the transverse slot. The catch is moveable between an extended position and a retracted position. A spring is mounted within the sleeve and includes a first arm engaged with the catch, a second arm extending outwardly from the sleeve, and a loop portion formed between the first and second arms. The first arm and the loop portion are retained within the sleeve. The door handle assembly further includes a handle assembly having an operator portion and a shank portion that extends out from the operator portion. The shank portion also has a transverse slot formed therein. The sleeve is received within the shank portion and a portion of the catch extends into the second slot when the catch is in its extended position. The first arm of the spring biases the catch into the extended position while the second arm biases the handle assembly tightly against the sleeve.  
         [0007]     Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]     The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:  
         [0009]      FIG. 1  is an exploded view of a door handle assembly having a lockset mechanism according to the principles of the present invention;  
         [0010]      FIG. 2  is an enlarged side view of a torsional spring of the lockset mechanism according to the principles of the present invention;  
         [0011]      FIG. 3  is a side sectional view of the lockset mechanism in which the handle and sleeve are in an uncoupled state;  
         [0012]      FIG. 4  is a side sectional view of the lockset mechanism shown in  FIG. 3  in a transitional state; and  
         [0013]      FIG. 5  is a side sectional view of the lockset mechanism shown in  FIG. 3  in a coupled state. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0014]     The following description of the preferred embodiment is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.  
         [0015]     Referring generally to the drawings, a door handle assembly constructed in accordance with the teachings of the present invention is generally indicated by reference numeral  10 . In the particular embodiment provided, the door handle assembly  10  is shown to include a handle assembly  12 , a sleeve  14 , a torsional spring  16 , and a catch  18 .  
         [0016]     The handle assembly  12  includes a shank portion  20  extending out from an operator portion  22 . The operator portion  22  is shown as a conventional doorknob, however, various other designs of the operator portion  22  may be employed, for example a lever handle. The shank portion  20  includes a bore  24  formed therein. The bore  24  extends from an end face  26  of the shank portion  20  to the operator portion  22 . A pair of grooves  28  are formed on an inner surface  30  of the bore  24 . The bore  24  and the grooves  28  are sized to receive the sleeve  14 , as will be described in greater detail below. A catch slot  32  formed in the shank portion  20  extends transversely from an outer surface of the shank portion  20  to the bore  24 . The catch slot  32  is sized to receive a portion of the catch  18 , as will also be described in greater detail below. A turnpiece shaft  34 , as seen in  FIGS. 3-5 , extends from the operator portion  22  through the shank portion  20  within the bore  24 . The turnpiece shaft  34  forms part of an operator locking mechanism for locking the door handle assembly  10  to prevent rotation of the handle assembly  12  with respect to a door (not shown). In the particular example provided, handle assembly  12  is shown to have a single, unitary construction. However, the shank portion  20  and the operator portion  22  may be constructed as separate pieces and assembled together using conventional methods.  
         [0017]     The sleeve  14  is generally cylindrical in shape and includes a pair of tabs  36  and a radial lip  38  formed on an outer surface thereof. The pair of tabs  36  extend from the lip  38  and fit within the pair of grooves  28  of the shank portion  20 . The portions of the sleeve  14  extending from opposite sides of the radial lip  38  form a first mounting portion  40  and a second mounting portion  42 . The first mounting portion  40  is received within operator  12  and the second mounting portion  42  is rotatably supported in a mounting plate (not shown) securable to the door. The sleeve  14  defines a cavity  44  that runs longitudinally through the sleeve  14 .  
         [0018]     The sleeve  14  further includes a slot  46  and a pair of holes  48 ,  50 . The slot  46  and hole  48  are formed in the first mounting portion  40  and the hole  50  is formed in the radial lip  38 . The slot  46  and holes  48  and  50  all extend from the outer surface of the sleeve  14  into the cavity  44  and are arranged in a longitudinal row with respect to the sleeve  14 . The slot  46  has a longitudinal portion  52  and a transverse portion  54  arranged in a cross-like shape. The radial portion  54  is sized to receive a portion of the catch  18  and the longitudinal portion  52  is sized to receive a portion of the torsional spring  16 , as will be described in greater detail below. The holes  48 ,  50  are sized to receive portions of the torsional spring  16 , which will likewise be described in greater detail below. It is to be understood that apertures of any particular shape may be employed for the slot  46  and holes  48 ,  50  so long as they are sized to perform their respective functions.  
         [0019]     A first support member  56  separates the longitudinal portion  52  of the first slot  46  from the hole  48 . A second support member  58  separates the hole  48  from the hole  50 . The support members  56 ,  58  are relieved from the surface of the sleeve  14  and have a reduced thickness with respect to the thickness of the sleeve  14 , as best seen in  FIGS. 3-5 .  
         [0020]     In the particular example provided, the sleeve  14  is made from a single piece die-cast metal. However, the sleeve  14  may also be formed from a combination of separate pieces each assembled and attached using conventional methods.  
         [0021]     The catch  18  is generally planar and includes an extension  62  extending out from a body  64 . An aperture  66  is formed within the body  64 . The extension  62  has a hole  68  formed therein and a sloped front face  70 . The hole  68  is sized to receive a portion of the torsional spring  16 . As indicated above, the extension  62  of the catch  18  is sized to fit within the transverse portion  54  of slot  46  in the sleeve  14  and the catch slot  32  of the handle assembly  12 .  
         [0022]     Referring to  FIG. 2 , the torsional spring  16  will now be described according to a preferred embodiment of the present invention. The torsional spring  16  includes a first arm  72 , a second arm  74 , and a loop portion  76  formed therebetween. The torsional spring  16  is made from a 21 gauge (0.031″). The loop portion  76  formed between the base portion  80  of the first arm  72  and the second arm  74  creates a 270 degree arc.  
         [0023]     The first arm  72  includes an end portion  78 , a base portion  80 , and a support portion  82  formed therebetween. In the preferred embodiment, the end portion  78  is angled down approximately 15 degrees with respect to the support portion  82 . The base portion  80  feeds into the loop portion  76  and is angled down approximately 25 degrees with respect to the support portion  82 . The first arm  72  has a length designated as I 1  in  FIG. 2 .  
         [0024]     The second arm  74  is angled up approximately 65 degrees with respect to the support portion  82 . The second arm  74  includes a bent portion  84  at its end. In the particular example provided, the bent portion  84  is angled approximately 180 degrees with respect to the second arm  74 . The second arm  74  has a length designated as  12  in  FIG. 2 . The length I 2  of the second arm  74  is approximately half the length I 1 , of the first arm  72 .  
         [0025]     Referring now to  FIG. 3 , the installation of the handle assembly  12  onto the sleeve  14  will be described. The catch  18  is mounted within the cavity  44  of the sleeve  14  such that the extension  62  extends through the slot  46 . The spring  16  is mounted within the sleeve  14  such that the loop portion  76  extends into the cavity  44  through hole  48 . The support portion  82  rests on the first support member  56 . The end portion  78  extends down through the longitudinal portion  52  of the slot  46  and engages the hole  68  of the catch  18 . The second arm  74  extends out from the hole  48  away from the sleeve  14 .  
         [0026]     Referring to  FIG. 4 , the handle assembly  12  slides onto the sleeve  14  as indicated by arrow A. The end face  26  of the shank  20  engages the sloped front face  70  of the catch  18 , urging the catch to a retracted position within the sleeve  14 . This urges the first arm  72  of the spring  16  downwards. The loop portion  76  is forced upwards but is retained in place by support member  58 . The turnpiece shaft  34  extends through the central aperture  66  of the catch  18 . As the handle assembly  12  moves in the direction of arrow A, the tabs  36  fit within the grooves  28  to radially align the handle assembly  12  with respect to the sleeve  14 .  
         [0027]     Referring to  FIG. 5 , as the handle assembly  12  is moved further in the direction of arrow A, the end face  26  engages the second arm  74  of the spring  16 . The second arm  74  is urged towards the sleeve  14  until the bent portion  84  at its end fits within the third slot  50  and the second arm  74  contacts the second support member  58 . The second arm  74  provides a biasing force radially outward against the handle assembly  12  to urge the handle assembly  12  tight against the sleeve  14 . This takes up any play between the handle assembly  12  and the sleeve  14 , resulting in a more solid feeling connection.  
         [0028]     When the catch slot  32  of the handle assembly  12  aligns with the first slot  46 , the spring  16  urges the catch  18  back to its extended position such that the extension  62  fits through the first slot  46  and the catch slot  32 . In this way, the catch  18  couples the handle assembly  12  relative to the sleeve  14 . To remove the handle assembly  12  from the sleeve  14 , the catch  18  is depressed down towards the sleeve  14  to its retracted position, and the handle assembly  12  may be removed in a direction opposite of arrow A.  
         [0029]     The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.