Abstract:
A door lock system comprising a first rotary configured to control extension and retraction of the deadbolt via a primary cam mechanism; a second rotary control configured to control extension and retraction of the latch; and a link configured to retract the deadbolt in response to operation of the second rotary control when the latch is retracted by the second rotary control. The link is configured to move along a linear path normal to the movement of the deadbolt and the door latch and to contact the primary cam mechanism upon the link movement to affect deadbolt retraction and extension. A lever may be used to retract the latch in response to rotation of the first rotary control in a first rotational direction when the deadbolt is retracted by the first rotary control.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. patent application Ser. No. 12/383,140, filed Mar. 20, 2009, now U.S. Pat. No. 9,222,286, the content of which is hereby incorporated by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    This invention relates generally to controlling the locking and unlocking of doors; and more particularly concerns provision of highly compact and improved mechanism for enabling operating of latches and deadbolts, as from opposite sides of doors. 
         [0003]    There is need for simple, highly compact, durable and efficient door locking and unlocking devices, where deadbolts and latches are to be operated, as from the inner and outer sides of doors. In particular, there is need for improvements in mechanism responsive to door handle turning, at the door inner side, with mechanism responsive to door unlocking at the door inner side, to secure both deadbolt release and door unlatching. 
       SUMMARY OF THE INVENTION 
       [0004]    It is a major object of the invention to provide improvements on apparatus meeting the above needs. Basically, and in accordance with the invention, a multi-function door lock system is provided, comprising: 
         [0005]    a) a frame having opposite sides, and installable on a door openable between an interior space and an exterior space, 
         [0006]    b) a deadbolt and a door latch carried by the frame to move between retractable and extended positions, 
         [0007]    c) a first rotary control located at one level on the frame to control deadbolt movement between extended and retracted positions via primary cam mechanism, 
         [0008]    d) a second rotary control at another level on the frame to control latch movement between extended and retracted positions, via secondary cam mechanism, 
         [0009]    e) means operatively connected between said secondary cam mechanism and said primary cam mechanism to effect deadbolt movement as aforesaid, in response to operation of the second rotary control, as effected via rotary input to the second rotary control from only one side of the frame. 
         [0010]    As will be seen, and in a preferred form of the invention, the above e) means includes a strut or link provided to extend between the secondary and primary cam mechanisms and bodily movable in response to the rotary input to said second rotary control. 
         [0011]    Another object includes provision of the first rotary control to have input means presented at opposite sides of the frame for effecting operation of the first rotary control from either side of the door to which the frame is installed; and provision of the second rotary control to have input means presented at opposite sides of the frame, for effecting operation of the second rotary control from either side of the door to which the frame is installed. 
         [0012]    Typically, finger and thumb operated rotors are provided at opposite sides of the frame, corresponding to opposite sides of a door carrying the frame, and are connected with the first rotary control for controlling deadbolt positioning. Also, and typically, handle levers are provided for operation at opposite sides of the frame, to be connected with the second rotary control, for controlling latch positioning. In this environment, only the lever at the inner side of the frame, and door, release both the deadbolt and door latch in response to turning of that lever. 
         [0013]    Yet another object is to provide split-cam means to operate in conjunction with operation of the first rotary control. And a further object is to provide second split-cam means to operate in conjunction with operation of the second rotary control and displacement of the strut. 
         [0014]    A further object includes provision of a selector means whereby turning of the handle at the door exterior optionally effects latch retraction and deadbolt retraction, simultaneously. 
         [0015]    An added object is to provide a deadbolt actuating lever, and two cam followers associated with the lever to be displaced in opposite rotary directions, respectively, to displace the deadbolt between extended and retracted positions, and in response to operation of a primary cam defined by said primary cam mechanism. 
         [0016]    An additional object is to provide a link having operative connection to said lever to displace the actuating lever in a rotary direction to effect extension of the deadbolt, in response to said rotary input to said second rotary control. 
         [0017]    A further object includes provision of means responsive to reverse rotation of the first rotary control to effect latch retraction independently of deadbolt displacement. 
         [0018]    These and other objects and advantages of the invention, as well as the details of an illustrative embodiment, will be more fully understood from the following specification and drawings, in which: 
     
    
     
       DRAWING DESCRIPTION 
         [0019]      FIG. 1  is an elevation showing a door edge with two inputs (latch key and handle) from the door extension side, and two inputs (finger and thumb, knob and door handle) from the door interior side; 
           [0020]      FIG. 2  is an elevation taken on lines  2 - 2  of  FIG. 1 ; 
           [0021]      FIG. 3  is an elevation taken on lines  3 - 3  of  FIG. 1 ; 
           [0022]      FIG. 4  is a vertical section taken on lines  4 - 4  of  FIG. 2 ; 
           [0023]      FIG. 5  is an elevation taken on lines  5 - 5  of  FIG. 4  and showing the frame and actuating mechanism within the frame, as viewed from the door interior side; both deadbolt and latch elements extended; 
           [0024]      FIG. 6  is an elevation taken on lines  6 - 6  of  FIG. 4 ; and showing both deadbolt and latch elements extended into openings in a door frame; and as viewed from the door exterior side; 
           [0025]      FIG. 7  is a view like  FIG. 5 , but showing the deadbolt retracted, and latch extended; 
           [0026]      FIG. 8  is a view like  FIG. 6 , but showing the deadbolt retracted and latch extended; 
           [0027]      FIG. 9  is a view like  FIG. 8  but showing both the deadbolt and latch retracted, whereby the door can freely swing between locations at opposite sides of the door frame; 
           [0028]      FIG. 10  is a view like  FIG. 5 , but showing locked positions of different actuator elements; 
           [0029]      FIG. 11  is a view like  FIG. 6 , but showing locked positions of different actuator elements; 
           [0030]      FIG. 12  is a view like  FIG. 10  but showing unlocked positions of the elements seen in  FIG. 10 ; 
           [0031]      FIG. 13  is a view like  FIG. 11  but showing unlocked positions of the elements seen in  FIG. 11 ; 
           [0032]      FIG. 14  is a fragmentary section taken on lines  14 - 14  of  FIG. 10 ; 
           [0033]      FIG. 15  is a fragmentary section taken on lines  15 - 15  of  FIG. 12 ; 
           [0034]      FIG. 16  is a fragmentary section, like  FIG. 15 , but viewing the frame with extended and interior sides reversed; 
           [0035]      FIG. 17  is a perspective view of an actuator arm seen in  FIGS. 12 and 13 ; 
           [0036]      FIG. 18  is a section showing holdback mechanism in engaged position; with latch bolt in extended position; 
           [0037]      FIG. 19  is like  FIG. 18  but shows the holdback mechanism in sidewardly disengaged position, with the latch bolt in retracted position; 
           [0038]      FIG. 20  is like  FIG. 19 , but with a hold back plate displaced downwardly into a groove in the retracted latch; 
           [0039]      FIG. 21  is an exploded view of the latch plate, the latch bolt; and the hold back plate retainer; 
           [0040]      FIG. 22  is a view like  FIG. 5 , but showing split cam structure, the deadbolt being in locked extended position, and the latch also being extended. 
           [0041]      FIG. 23  is an enlarged section taken on lines  23 - 23  of  FIG. 22 ; 
           [0042]      FIG. 24  is a view like  FIG. 6 , and showing split cam mechanism in deadbolt extended and locked position, with a deadlock arm in actuated position; 
           [0043]      FIG. 25  is a view like  FIG. 24 , showing the deadlock arm moved away from the deadbolt to allow deadbolt release; 
           [0044]      FIG. 26  is a view like  FIG. 25 , showing elements when deadbolt and latch are retracted; 
           [0045]      FIG. 27  is a section taken on line  27 - 27  of  FIG. 24 , elements being locked; 
           [0046]      FIG. 28  is a view like  FIG. 27 , showing elements in unlocked positions; 
           [0047]      FIG. 29  is a plan view section taken on lines  29 - 29  of  FIG. 24 , elements being locked; 
           [0048]      FIG. 30  is a section taken on lines  30 - 30  of  FIG. 29 ; 
           [0049]      FIG. 31  is an exploded perspective view showing split cam mechanism; 
           [0050]      FIG. 32  is a perspective view of mechanism elements; and 
           [0051]      FIG. 33  is a view similar to  FIG. 32 , but showing additional elements. 
       
    
    
     DETAILED DESCRIPTION 
       [0052]    In the drawings, a preferred multi-function door lock system or apparatus  10 , has a mounting frame  11  sized for insertion into a door opening  11 ′. 
         [0053]    The frame has opposite sides  12  and  13  which respectively face toward the door exterior  14 , and the door interior  15 . The front side  16  of the frame is carried by a mounting plate  17  held in position by fasteners  18 , as seen in  FIG. 1 . As also seen in  FIG. 2 , a deadbolt  19  is carried by the frame to protrude from the plate  17 , via opening  20 , as the bolt is moved between extended position  19   a  (see  FIG. 6 ) and retracted position  19   b  in the frame (see  FIG. 7 ); and a latch bolt or latch  21  is carried by the frame to protrude from plate  17  via opening  22 , as it is moved between extended position  21   a  and retracted position in the frame. Elongated frame structure appears at  11   a - 11   d . See  FIGS. 10 and 11 . 
         [0054]    A first rotary control such as rotary actuator  25  is located at one level on the frame, at the interior side of the door, for example, to control deadbolt movement between extended and retracted positions via compact mechanism in the frame. That mechanism typically includes primary cam  26 . Actuator  25  is typically gripped by the user&#39;s thumb and finger, to be turned in operating the deadbolt. A second rotary control, such as handle  27  is located at a second and typically lower level, to project from the frame, at the interior side of the door, for example, to control latch  21  movement between extended and retracted positions via compact mechanism in the frame, that mechanism typically including secondary cam mechanism  28 . See  FIG. 5 . 
         [0055]      FIG. 1  also shows a key  29  projecting or inserted via keyhole  29  at the exterior side of the door, i.e. opposite from rotary actuator  25 , to be operatively connected with the first rotary control for moving the deadbolt (as between extended or locking positions, and a retracted or unlocking position). Also  FIG. 1  shows a second handle or handle lever  32 , projecting at the exterior side of the door, and at the opposite side of the frame from handle  27 . Handle  32  is operatively connected with the second rotary control mechanism as is handle  27  to control latch movement between extended and retracted positions, in response to manual down-turning of handle  32 , at the exterior side of the door. 
         [0056]    Latch movement between extended and retracted positions occurs in response to turning of either of handles  27  and  32  as effected via compact secondary cam mechanism  28 . 
         [0057]    It is a feature of the invention that means is provided and operatively connected between the secondary cam mechanism  28  and primary cam mechanism  26  comprised of upper split cam parts  55  and  55   a  and arms  39  and  39   a  to effect deadbolt movement as aforesaid in response to operation of said second rotary control, as effected via rotary input to said second rotary control from only one side of the frame. Thus, for example, as interior side handle  27  is turned to turn shaft  27   a , not only is the latch retracted from extended position in engagement with the door frame or associated hardware, at opening  22 , (see  FIGS. 12 and 13 ) but also the deadbolt is retracted from extended position in engagement with the door frame or associated hardware, whereby a person trapped at the door interior side (building room side) can quickly escape from that interior by opening the deadbolt locked and latch engaged door in response to emergency turning of handle  27  alone; this occurs even though actuator  25  and key  29  are not manipulated. This is enabled by provision and operation of lower secondary cam mechanism  28  situated on each of split hubs  40  and  40   a  effecting downward translation of a link  36  (see  FIG. 12 ) which extends upwardly into operative engagement or connection with compact upper or primary split cam mechanism  26 , which in turn effects deadbolt retraction from locking or extended positions. In this regard, as the secondary split cam mechanism is operated by handle  27 , the latch is retracted from engagement with the door frame or associated hardware. As a result, the door is completely unlocked, i.e. is free for swinging to allow “panic” escape. See in this regard lower split cam mechanism arm  50  in  FIGS. 12 and 25 , rotating into engagement with foot  36   a  of link  36  to displace  36  downwardly, as in  FIG. 25 . This causes or effects downward movement of arm extension  36   a ′, pin guided at  36   c , to push pin  38   a  down to engage arm  38 , rotating it and actuating arm  39  clockwise in  FIG. 25 . This causes downward and leftward movement of actuating arm  39 , of the upper split cam (see also  FIG. 31 ), so that a pin  39   b  extending in deadbolt slot  49  retracts the deadbolt due to pin  39   b  movement to the left, in vertical lost motion slot  49  in the deadbolt  19 , retracting the deadbolt to the left, in  FIG. 26 . Arms  39  and  39   a  of the upper split cam extend from hubs  39 ′ and  39   a ′, in  FIG. 31 . The arms are assembled side by side. See  FIG. 30 . 
         [0058]    In this regard, return of the deadbolt to the right in  FIG. 24  is effected by rotation of key  29  or by actuator  25 , rotating the rotor  53  clockwise in  FIG. 24 . A lug  53   a  on  53  then cams or rotates the upper split cam part  55  counterclockwise, which rotates  39   a  counterclockwise, pushing the deadbolt to the right, via pin  39   a  movement in slot  49 . Alternatively, rotation of rotor  53  counterclockwise by the key causes lug  53   a  to push the corresponding upper split cam part  55   a  and actuating arm  39  clockwise to retract the deadbolt. 
         [0059]      FIGS. 8 and 9  also show mechanism to retract the latch  21  in response to reverse (counter-clockwise) rotation of rotor  53  by either of actuator  25  or key  29 , seen in Fig. As shown, dog or lug  53  on rotor  53   a  (rotated counterclockwise) engages projection  61   a  on lever  61 , pivoted at  62 , to rotate  61  counterclockwise. Lower extension  61   b  on  61  then engages protrusion  56  associated with the secondary cam mechanism to retract the latch. That mechanism includes a split hub  40  and secondary cam mechanism  28  which rotates clockwise in  FIGS. 5 and 12  to engage and displace lug  42  on the latch body  21   a , ( FIG. 6 ) retracting the latch to the right in  FIG. 5 , against compression spring  43 . 
         [0060]    Arm  50  on the hub  40  is rotatable to displace foot  36   a  on link  36  downwardly. This movement causes downward translation of link  36  (see  FIGS. 12-17 and 26 ) effecting or enabling retraction of the deadbolt, via operation of the primary cam mechanism, as referred to above. Part  406  in  FIGS. 5 and 6  does not dog secondary cam mechanism  28  but is axially spaced between  28  and  28   a.    
         [0061]    In this regard, counterclockwise turning of rotor  53  in  FIG. 24  in response to turning of key  29  causes lug  53   a  on the rotor to engage the primary split cam extension  55   a  on arm  39  and thereby rotate that arm clockwise in  FIG. 25  for retracting the bolt. Rotor  53  is also rotatable by the actuator  25  at the interior side of the door, enabling unlocking of the deadbolt. 
         [0062]    In  FIGS. 5-9, and 17 , and as referred to, secondary cam mechanism  28  carried by rotary split hub part  40  is operable upon handle actuated rotation of  40  to rotate and engage lug  42  on the latch to push the latch into retracted position. As referred to, rotation of  28  is effected by handle  27  at the inner side of the door, which also effects deadbolt retraction, via link  36 . See  FIGS. 14, and 25 . In addition, rotation of companion split hub part  40   a  by the exterior side handle  32  (see  FIG. 5 ) effects latch retraction via rotation of a secondary cam mechanism to engage protrusion  56  on the latch, (see  FIG. 8 ) to push the latch into retraction, but without affecting the status of the deadbolt. To retract the deadbolt, the key  29  must be inserted and turned, to rotate rotor  53 , as referred to above. 
         [0063]      FIGS. 18-21  show the provision of hold back plate  95  movable downwardly, as seen in  FIG. 20 , to effect insertion of the plate lower tip portion  95   a  into a groove  76  in the top of the latch  21 . This holds the latch against movement into latching position. Plate  95  is carried by the frame for sliding movement. A serrated pusher  97  associated with the plate protrudes at  97   a  for thumb actuation, as seen in  FIG. 1 . A hold back plate retainer  98  is engageable by a rightwardly movable clutch  79  (see  FIGS. 18 and 19 ) actuated by the pivotable extension  55   a  of the cam part  55 , pivoted at  62   a . When lever  61  is moved leftwardly to bring groove  76  into registration with hold back plate tip portion  95   a , as by clockwise rotation of rotor  53 , the latch  21  is displaced to the left, by lower extent of cam part of lever  61 , to bring groove  76  into vertical registration with hold back tip  95   a , at which time the hold back is movable downwardly, allowing the teeth  99   a  on clutch  79  to engage teeth  98   a  on the retainer  98  carried by the plate  95 , locking the latch in retracted position. 
       Summary of User Operation 
       [0064]    1. From exterior side of door, key  29  is turning to unlock (retract) the deadbolt  19 . Then handle  32  is turned to retract latch  21 , to open door, and also perform this function in case deadbolt was already retracted. 
         [0065]    2. From interior side of door, rotary actuator  25  is turnable to unlock (retract) the deadbolt. Also, actuator  25  is turnable to effect retraction of latch  21 , via lever  61 . This enables operation of the hold back  95  and pusher  97  to enable door to swing freely. 
         [0066]    3. From interior side of door, handle  27  can be turned to retract both latch and the deadbolt, as in an emergency.