Abstract:
A locking system for a moveable member supported by a support frame, the support frame having an engagement surface, the locking system comprising a lock member and an input device adapted to be mounted on the moveable member the input device being operably connected to the lock member. The input device is rotatable to move the lock member from a first position to a second position, the second position defining a locked position wherein the lock member is adapted to be in contact with the engagement surface. Means for allowing additional rotation of the input shaft after the lock member reaches the locked position is also provided.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. application Ser. No. 11/039,115, filed Jan. 20, 2005, which is a continuation of U.S. application Ser. No. 10/107,518, filed Mar. 27, 2002, now U.S. Pat. No. 6,871,451, which applications are incorporated herein by reference and made a part hereof, and upon which a claim of priority is based. 
     
    
     FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not applicable. 
       TECHNICAL FIELD 
       [0003]    This invention relates generally to a lock unit for a sliding sash. More particularly, it relates to a multipoint lock assembly for a sliding door or window sash. 
       BACKGROUND OF THE INVENTION 
       [0004]    Various types of sliding door or window assemblies are well known in the art. For example, a typical sliding door assembly may be used in a residential setting such as for a patio door. Such sliding door assemblies typically include two door sashes mounted within a master frame. One door sash may be stationary or remain in a fixed position relative to the master frame. The other door sash may typically be slidably mounted within the master frame. Alternatively, one or both of the door sashes can be hingedly connected to the master frame to be swinging doors. 
         [0005]    A variety of types of locking mechanisms have typically been provided for these sliding door assemblies. A simple single point lock mechanism has been provided that includes a finger that engages a keeper on the door frame, holding the door in a closed position. This type of lock is simple to manufacture and simple to operate. However, it provides only a limited measure of security and can be relatively easily overcome in a forcible entry. 
         [0006]    Multipoint lock assemblies are also known in the art. Typically, these assemblies include a plurality of keepers mounted to the frame. They also include a lock unit that mounts to an edge of the sliding door sash. The lock unit includes a corresponding plurality of latch members and a latch actuation unit. When the door is closed, the latch actuation unit is used to cause the latch members to engage the keepers, thereby preventing the door from being opened. 
         [0007]    A disadvantage of known multipoint lock assemblies is that they are often complicated making them expensive and difficult to manufacture. They often include complicated lock actuators, latches and keepers. They also typically include complicated link mechanisms between moving parts along their lengths. 
         [0008]    A further disadvantage is that multipoint lock assemblies require precise alignment between each keeper and its corresponding latch member. This alignment must be made at the time of installation and maintained through the life of the lock assembly. If proper alignment is not achieved or maintained, the lock assembly will not function properly. Misalignment may result in an inability of the latch mechanisms to engage the keepers or to be placed and maintained in a positively locked position. Misalignment may also result in damage to the latches or other components 
         [0009]    A further disadvantage is that past lock units have been able to be activated while the door is in an open position. This places the latches in an engaged position while the latches are at a distance from the keepers. If the door is then closed before moving the latches back to an open or unlocked position, damage can result to the keepers, the latches or other aspects of the lock unit. 
         [0010]    A further disadvantage is that typical multipoint lock units and their actuators cannot accommodate for misalignment that may occur over the course of time throughout the life of the unit. 
         [0011]    A further disadvantage is that the latch members of the lock units are not typically as sturdy or strong as one would desire to ensure an appropriate measure of security. 
         [0012]    The present invention is provided to solve these and other problems. 
       SUMMARY OF THE INVENTION 
       [0013]    The present invention provides a multipoint lock assembly for a door assembly or window assembly. The door or window assembly has a movable member such as a door or window sash supported by a support frame. 
         [0014]    According to a first aspect of the invention, a locking system for a moveable member supported by a support frame is provided, the support frame having an engagement surface. The locking system includes a lock member and an input device adapted to be mounted on the moveable member, the input device being operably connected to the lock member. The input device is rotatable to move the lock member from a first position to a second position, the second position defining a locked position wherein the lock member is adapted to be in contact with the engagement surface. Also according to a first aspect of the invention, means for allowing additional rotation of the input shaft after the lock member reaches the locked position is provided. 
         [0015]    According to another aspect of the invention, the means for allowing additional rotation includes an elastic connection between the lock member and the input device. 
         [0016]    According to another aspect of the invention, the means for allowing additional rotation includes a link arm connected between the input device and lock member, the link arm being slideable relative to the lock member when the lock member is in the locked position. 
         [0017]    According to another aspect of the invention, the means for allowing additional rotation includes a spring having one end connected to the input device and another end connected to the lock member. 
         [0018]    According to another aspect of the invention, the means for allowing additional rotation allows the input device to rotate to a position defining a locked position. 
         [0019]    According to another aspect of the invention, a locking system for a door movably mounted in a door frame is provided, the door frame having an engagement surface. The locking system includes an input device adapted to be mounted on the door and rotatable from a first position to a second position and a link arm having a first end and a second end, the first end being connected to the input device. A lock member having a lock surface is also provided, the lock member being associated with the link arm. A spring is provided having a first end connected to the link arm and a second end connected to the lock member, wherein the link arm and spring move the lock member in response to rotational movement of the input device from the first position to an intermediate position wherein the lock member moves from an unlocked position to a locked position, wherein the lock surface contacts the engagement surface, wherein the operable connection between the link arm and lock member allows the link arm to move relative to the lock member to allow the input device to be further rotated to the second position. 
         [0020]    According to another aspect of the invention, the second end of the link arm has a slot therein and the locking member has a pin being received by the slot. 
         [0021]    According to another aspect of the invention, the second end of the spring is connected to the pin. 
         [0022]    According to another aspect of the invention, the locking system includes a latch mounted to the door frame defining the engagement surface and an aperture defining the lock surface wherein the aperture receives the latch. 
         [0023]    According to another aspect of the invention, the locking system includes an upper extension operably connected to the lock member, the upper extension having an upper lock surface, wherein the link arm and spring move the upper extension in response to rotational movement of the input device from the first position to the intermediate position wherein the upper lock surface contacts an upper engagement surface of the door frame. 
         [0024]    According to another aspect of the invention, the locking system the operable connection between the link arm and lock member allows the link arm to move relative to the lock member to allow the input device to be further rotated to the second position after the upper lock surface contacts the upper engagement surface. 
         [0025]    According to another aspect of the invention, the locking system also includes an upper latch mounted to the door frame defining the upper engagement surface and an upper aperture defining the upper lock surface wherein the upper aperture receives the upper latch. 
         [0026]    According to another aspect of the invention, the locking system also includes a lower extension operably connected to the lock member, the lower extension having a lower lock surface wherein the link arm and spring move the lower extension in response to rotational movement of the input device from the first position to the intermediate position wherein the lower lock surface contacts a lower engagement surface of the door frame. 
         [0027]    According to another aspect of the invention, the operable connection between the link arm and lock member allows the link arm to move relative to the lock member to allow the input device to be further rotated to the second position after the lower lock surface contacts the lower engagement surface. 
         [0028]    According to another aspect of the invention, the locking system also includes a lower latch mounted to the door frame defining the lower engagement surface and a lower aperture defining the lower lock surface wherein the lower aperture receives the latch. 
         [0029]    According to another aspect of the invention, the input device further comprises a shaft and the link arm further comprises a hook formed from the first end of the link arm, wherein the hook is biased to receive the shaft when the input device is in the second position. 
         [0030]    According to another aspect of the invention, the lock member has u-shaped cross section. 
         [0031]    Other features and advantages of the invention will be apparent from the following specification taken in conjunction with the following drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0032]    The multipoint lock assembly of the invention will now be described with reference to the accompanying drawings, in which: 
           [0033]      FIG. 1  is an elevation of a sliding door assembly having a mulit-point lock assembly of the present invention shown in phantom; 
           [0034]      FIG. 2  is an isometric view of an embodiment of the multipoint lock assembly of the present invention; 
           [0035]      FIG. 3  is an exploded view of a lock actuator of a sliding lock unit of the multipoint lock assembly; 
           [0036]      FIG. 4  is an isometric view of a case mount of the lock plate assembly; 
           [0037]      FIG. 5  is an isometric view of the case mount of  FIG. 4  at a different angle of perspective than that of  FIG. 4 ; 
           [0038]      FIG. 6  is an exploded view of an extension assembly of the multipoint lock assembly; 
           [0039]      FIG. 7  is a partial side view of the lock assembly with a side plate of the lock actuator removed; 
           [0040]      FIG. 8  is an isometric view of an input device of the lock actuator; 
           [0041]      FIG. 9  is a side view of a link arm of the lock actuator; 
           [0042]      FIG. 10  is an isometric view of the link arm; 
           [0043]      FIG. 11  is an isometric view of an actuation member of the lock actuator; 
           [0044]      FIG. 12  is a partial exploded view of a strike unit of the lock assembly; 
           [0045]      FIG. 13  is a partial side view in cross section of the strike plate assembly; 
           [0046]      FIG. 14  is a partial side view of the lock assembly showing the input device in an intermediate position; 
           [0047]      FIG. 15  is a partial side view of the lock assembly showing the input device in an in-line position; 
           [0048]      FIG. 16  is a partial side view of the lock assembly showing the input device in an a second or overrotated position; 
           [0049]      FIG. 17  is a partial side view of the lock assembly showing the input device in a mis-aligned intermediate position; 
           [0050]      FIG. 18  is a partial side view of the lock assembly showing the input device in a mis-aligned in-line position; and 
           [0051]      FIG. 19  is a partial side view of the lock assembly showing the input device in a mis-aligned overrotated position. 
       
    
    
     DETAILED DESCRIPTION 
       [0052]    While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated. 
         [0053]      FIG. 1  shows a sliding door assembly  10  having a sliding panel  12  and a fixed panel  14  mounted within a master door frame  16 . A lock assembly  42  of the present invention is shown in phantom. The sliding panel  12  is adapted for reciprocal sliding movement within the master frame  16 . The fixed panel  14  remains stationary with respect to the master frame  16  and is fixed thereto. The sliding panel  12  can be considered a movable member and the door frame  16  can be considered a support frame. 
         [0054]    The sliding panel  12  includes a pair of vertical stiles  18 , and a pair of horizontal members  22  and  24  that cooperate to form a frame  25 . A glass pane  26  is fitted within the frame  25 . It is understood that the invention may be equally used with panels  12 ,  14  that are solid, rather than including a glass pane  26 . The master frame  16  includes a horizontal header  27 , horizontal footer  28 , a left jamb  30  and aright jamb  32 . An upper track  34  is mounted to or integrally formed in the horizontal header  26  and a lower track (not shown) is mounted to or integrally formed in the horizontal footer  28 . A jamb channel  35  is mounted to or integrally formed in the left jamb  30 . A recess  19  is formed into the edge of the vertical stile  18 . While in a preferred embodiment, the door assembly  10  is a sliding door assembly, it is understood that the present invention can be configured to be installed in a swinging door assembly. It is further understood that the present invention can be incorporated into window assemblies or other applications having a movable member supported by a support frame. 
         [0055]    The lock assembly  42  is comprised of a sliding lock unit  44  and a strike unit  46  ( FIG. 2 ). As generally shown in  FIG. 1 , the sliding lock unit  44  is mounted to the sliding panel  12 , partially within the vertical stile  18 , as described in detail below. The strike unit  46  is mounted in the jamb channel  34 , as described in detail below. In alternative embodiments, the sliding door assembly  10  may comprise at least two sliding panels  12 . In this embodiment, the panels  12  slide towards each other to close the door assembly via abutting vertical stiles  18  of the respective panels  12 . The lock assembly  42  secures the abutting stiles  18  to one another to prevent the panels  12  from being separated. Additional stationary panels may be associated with the sliding panels. 
         [0056]    The sliding lock unit  44 , as shown in  FIGS. 2-3 , includes a lock member assembly  48  and a lock actuator  50 . The lock member assembly  48  includes a face plate  52 , and a lock member  54 . 
         [0057]    The face plate  52  is formed from a piece of flat steel and has a centrally located aperture  60 . The face plate  52  is sized to be mounted to an edge of the sliding panel  12 . 
         [0058]    In a preferred embodiment, the lock member  54  includes a central portion  55  and a pair of extension assemblies  59 . Furthermore, it is understood that the lock member  54  may include any number of extension assemblies  59 . However, it is understood that the lock member  54  may be comprised of only the central portion  55  and remain within the scope of the invention. The central portion  55  has a base  62  having an aperture  72 . The aperture  72  defines a lock surface  73  ( FIG. 7 ). Extending generally perpendicularly from the base  62  is a first side wall  64  and a second side wall  66 . The base  62 , the first side wall  64  and the second side wall  66  combine to give the central portion  55  a generally U-shaped cross section. In alternative embodiments, the central portion  55  may have a generally flat cross section. The first side wall  64  includes a tab  68  and a safety notch  78 . A pivot pin or post  212  extends from the tab  68 . An additional safety notch  78  is located on the second side wall  66 . The lock member  54  is slidably mounted to the face plate  52  via a pair of case mounts  82 , as shown in  FIGS. 3-5 . Similarly, the extensions assemblies  59  may be integrally formed with the central portion  55  or the face plate  52 . 
         [0059]    Each extension assembly  59  is identical to the other. Therefore, only one extension assembly  59  is described. ( FIGS. 2 and 6 ) The upper extension assembly  59  includes a drive arm  56  and an extension portion  132 . However, it is understood that the upper extension  59  may include only the extension portion  132  while remaining within the scope of the invention. The extension portion  132  is generally U-shaped, similar to the U-shaped cross section of the central portion  55 . It is understood that the extension portion  132  may have a flat cross section, as well. The extension portion  55  has an extension aperture  142  defining an extension lock surface  145 . The drive arm  56  is formed from a flat piece of steel and is operably connected to both the central portion  55  and the extension portion  132 , as shown. It is further understood that the extension assemblies  59  can vary in length. 
         [0060]    Referring to  FIGS. 2 ,  3  and  7 , the lock actuator  50  of the sliding lock unit  44  includes a housing  156 , an input device  158 , a link arm  160 , an overcenter spring  162 , a safety spring, or actuation or deflectable member  164  and a return spring  165 . The housing  156  includes a pair of side plates  157  attached to one another via four pins  210 . 
         [0061]    The input device  158  is rotatably mounted to the housing  156  and has a generally cylindrical shaft  172 , as shown in  FIGS. 7-8 . Extending radially and generally perpendicular to an exterior surface of the input body  172  is a radial tab or offset arm  174  having a pair of opposed ears  176 . Additionally, a slot  178  extends through the cylindrical input shaft  172  for mounting a thumb screw or thumb turn as is commonly known in the art. 
         [0062]    The link arm  160 , as also seen in  FIGS. 9-10 , has a first end  180  having a hook  182  integrally formed therein. The first end  180  also has a pair of opposed ear holes  184 . A second end  186  of the link arm  160  has a slot or opening  188  having a length and a proximal end  190  and a distal end  192 . The second end  186  also includes a spring slit  189 . A spring-catch  194  is formed in the link arm  160  and is located in between and generally in line with the oblong slot  188  and the ear holes  184 . The link arm  160  also includes a return-spring eyelet  195 . 
         [0063]    The overcenter spring  162  includes a coil  196 , an extended hook  198  at one end and a short hook  200  at another end. The plane defined by the extended hook  198  is generally perpendicular to the plane defined by the short hook  200 . 
         [0064]    The actuation member  164  as also seen in  FIG. 11  is formed from a flat piece of steel and has a static end  202  and a dynamic or distal end  204 . The static end  202  is formed into an L-shape. The dynamic end  204  is generally T-shaped having a pair of opposed protrusions or stop tabs  208  extending therefrom. The actuation member  164  also has an intermediate portion  203  having an exterior surface  205 . A dimple  206 , is located on the exterior surface  205 . 
         [0065]    In an assembled state of a preferred embodiment of the lock actuator  50 , the housing  156  is mounted to the face plate via case mounts  82 . ( FIGS. 3-5 ). 
         [0066]      FIGS. 2 ,  7  and  14 - 19 , show the lock actuator  50  in an assembled state with one side plate  156  removed to more easily depict the internal components of the lock actuator  50 . Referring to  FIGS. 2 and 7 , the shaft  172  of the input device  158  is rotatably mounted to the side plates  156 . The ears  176  at the distal end of the offset arm  174  are received by the ear holes  184  to rotatably mount the first end  180  of the link arm  160  to the input device  158 . 
         [0067]    The link arm pivot pin  212  is received by the slot  188  of the link arm  160 . The extended hook  198  is connected to the link arm pivot pin  212  through the spring slit  189 . The short hook  200  is attached the spring-catch  194 . The overcenter spring  162  thus biases the proximal end  190  of the slot  188  towards the pivot pin  212 . Accordingly, the second end  186  of the link arm  160  is slidably and rotatably mounted to the lock member  54 . That is, the link arm  160  both rotates about the pivot pin  212  and may slide with respect to the pivot pin  212  such that the pivot pin  212  moves relatively along the length of the slot  188 . Additionally, one end of the return spring  165  is connected to the return-spring eyelet  195  and another end of the return spring  165  is connected to a pin  210 . 
         [0068]    The static end  202  of the actuation member  164  is mounted to the housing  156  such that the exterior surface  205  is located generally adjacent to the aperture  72  of central portion  55 , as can be seen in a preferred embodiment depicted in  FIGS. 2 ,  3 , and  7 . Also, then, the dimple  206  is located at least partially with the aperture  72 . It can be seen that the stop tabs  208  of the dynamic end  204  are adapted to engage the safety notches  78 . Furthermore, because the actuation member  205  is formed from a flat piece of steel, it is spring like and its dynamic end  204  is biased to an engaged position as shown in  FIG. 7 . 
         [0069]    The strike unit  46  can be seen in  FIGS. 2 ,  12 , and  13  and includes latches  214  and a connector bar  218 . Each latch  214  defines an engagement surface  220 . In a preferred embodiment of the strike unit  46 , as shown in  FIG. 2 , the strike unit  46  includes a centrally located latch  214 , an upper latch  214  and a lower latch  214 . Each latch  214  is mounted to the connector bar  218  by conventional means known in the art. Each latch  214  is also mounted on the connector bar  218  at a predetermined distance from the other latches  214 . 
         [0070]    As previously mentioned the sliding lock unit  44  of the lock assembly  42  is installed in the recess  19  of the stile  18 . The recess  19  and the sliding lock unit  44  are adapted such that when the sliding lock unit  44  is installed in the recess  18 , the exterior surface  53  of the face plate  52  is flush with the edge of the stile  18  and all other components of the sliding lock unit  44  are located within the stile  18  and hidden thereby ( FIG. 1 ). The sliding lock unit  44  may be secured to the stile  18  by any conventional means such as screws or bolts or other known fasteners 
         [0071]    The strike unit  46  is installed into the jamb channel  34  of the left jamb  30 . Similar to the sliding lock unit  44 , the strike unit  46  may be secured to the jamb by any conventional means. The jamb channel  34  may be adapted so that the strike hooks  214  do not extend beyond the depth of the jamb channel  34 . 
         [0072]    The strike unit  46  must be properly aligned with respect to the sliding lock unit  44  before securing the strike unit  46  to the jamb channel  34 . The strike unit  44  is properly aligned when each latch  214  is aligned with one of respective apertures  72  or  142  of the lock member assembly  48 . Once properly aligned, each latch  214  will be received by its respective aperture  72 , or  142 , once the sliding panel  12  is slid to a closed position. Because each of the latches  214  are located at a predetermined distance from one another, once one latch  214  is properly aligned, the other latches  214  are also automatically properly aligned with their respective apertures. There is no need to separately align each of the three latches  214 . 
         [0073]    As depicted in  FIG. 7 , the input device  158  is in a first position and the central portion  55  is in an unlocked position. This configuration is maintained while the sliding panel  12  is in its open position, by engagement of the safety notches  78  by the stop tabs  208 . As the sliding panel  12  is being closed ( FIG. 14 ), the centrally located latch  214  passes into and through the aperture  72 . Because of the previously discussed automatic alignment, the upper and lower latches  214  also pass into their respective apertures  142 . 
         [0074]    As the central strike hook  214  passes into the aperture  72  of the central portion  55 , it contacts and engages the dimple  206  of the exterior surface  205 . This, in turn, displaces the dynamic end  204  to an un-engaged position disengaging the stop tabs  208  from their respective safety notches  78 . This allows sliding movement of the central portion  55 . The height of the dimple  206  can vary to fine tune the actuation of the actuation member  164 . 
         [0075]    Once the sliding panel  12  has been fully closed and the safety spring  164  disengaged as described, the input device  158  may be rotated from the first position ( FIG. 7 ) to an intermediate position as shown in  FIG. 14 . This rotation also moves the center portion  55  from its unlocked position to a locked position wherein the locking surface  73  of the center portion  55  comes into close, interfering abutment with the engagement surface  220  of the central latch  214 . Also, the rotation of the input device  158  from the first to intermediate positions results in each extension portion  132  moving from an unlocked position to a locked position wherein its locking surface  145  is in close, interfering abutment with the engagement surface  220  of its respective latch  214 . The interference between the locking surfaces  73  and  145 , with the engagement surfaces  220  prevents the panel  12  from being slid away from the jamb  30 . 
         [0076]    The input device  158  may then be rotated from the intermediate position shown in  FIG. 14 , to a second position of overrotation shown in  FIG. 16 . In doing so, the link arm  160  continues to rotate about the pivot pin  212 . Additionally, overcenter spring  162  elastically elongates and the proximal end  190  of the slot  188  moves away from the pivot pin  212 , as shown in  FIGS. 15 and 16 . This provides the necessary radius of rotation to allow the input device  158  to rotate past an in-line position shown in  FIG. 15  to the second position shown in  FIG. 16 . In the second position, the integral hook  182  is biased to receive the input shaft  172  of the input device  158 . 
         [0077]    To unlock and open the sliding sash  12 , the input device  158  is rotated from the second position to the first position. In doing so, the input device  158  passes through the intermediate position and moves the center portion  55  from the locked position to the unlocked position. Once the input device has been rotated to the first position, the sash  12  may be slid away from the jamb  30 . It can be understood that the return spring  165  assists in ensuring that the input device  158  is fully returned to the first position of  FIG. 7  when unlocking the lock member  54 , minimizing the chance for the input device  158  to remain in an intermediate position. Additionally, the return spring  165  provides a desirable feel to the operator while manipulating the input device  158 . 
         [0078]    Over time, the latches  214  may become slightly misaligned due to shifting of the connector bar  218 , or damage to a latch  214  from a variety of potential sources. Or the misalignment may result from an improper initial alignment during installation. This may result, for example, in the central latch  214  passing through the aperture  72  in a position lower than that previously shown and described in  FIGS. 14-16 , as the sash is slid to its closed position. An example of this misalignment is shown in  FIG. 17 . In this scenario, rotation of the input device  158  from its first position towards its second position, results in the input device  158  reaching its intermediate position through a smaller angle of rotation than as described and shown above in the scenario where all latches are properly aligned. This misaligned intermediate position of the input device  158  is shown in  FIG. 17 . The input device  158  may then be rotated through the misaligned intermediate position ( FIG. 18 ) and to its misaligned second position ( FIG. 19 ). In doing so, the proximal end  190  of the slot  188  moves away from pivot pin  212 . It can be seen that in the situation of a misaligned latch  214  ( FIGS. 17-19 ), the proximal end  190  moves farther away from the pivot pin  212 , than in the situation wherein all the latches  214  are properly aligned, as is previously described and shown in  FIG. 14-16 . It can be seen then, that the length of the slot  188 , cooperates with the overcenter spring  162  to permit the lock actuator  50  to automatically compensate for a range of misalignment of the latches and to allow the input device  158  to be rotated to an overrotated position. 
         [0079]    It is noted at this time that additional embodiments may include a resilient member rather than the link arm as described and remain within the scope of the present invention. Also, the invention can be applied to either sliding or swinging doors or windows. As previously mentioned, it may also be applied to sliding doors or windows that include multiple sliding members. 
         [0080]    While the specific embodiments and various details thereof have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention and the scope of protection is only limited by the following claims.