Abstract:
A throw member having a first and second hub located along a blade that couples the rotation of the core cylinder with the rotation of the key cam of a lock chassis to lock and unlock a lock assembly. The two hubs are spaced apart to receive a catch. The catch constrains the throw member from releasing when the core cylinder or door lever is exchanged or modified. In addition, the two hubs enhance the throw member&#39;s ability to prevent unauthorized removal of the door lever. One of the two hubs includes a passage to release the throw member from the catch.

Description:
FIELD OF THE INVENTION 
   The present invention relates to a lock assembly. In particular, the present invention relates to a lock assembly that includes a self-contained throw member. 
   BACKGROUND OF THE INVENTION 
   In general, door lock assemblies are actuated by levers or knobs. Many door levers include a core cylinder with lock key mechanism for locking and unlocking the lock assembly. For these types of lock assemblies, consumers and manufacturers desire a lock assembly having a door lever and/or core cylinder that is readily exchangeable as well as secure. 
   SUMMARY OF THE INVENTION 
   The present invention provides a throw member located in the drive spindle that couples the core cylinder with the lock. The throw member of the invention enhances a lock assembly having a core cylinder, because the core cylinder can be exchanged or modified without the throw member coming loose. In addition, the throw member can be inserted or removed without the use of additional tools. 
   In one embodiment, the invention provides a throw member for a lock assembly, the throw member including a blade having a first end and a second end, the second end for engaging a key cam operable in retracting the lock assembly, a first hub located at the first end of the blade, a second hub located at a distance along the blade apart from the first hub, and an extension to the first hub for engaging a core cylinder having a key mechanism, wherein rotation of a key inside the key mechanism of the core cylinder is operable in rotating the throw member and key cam of the chassis in retracting the lock assembly. 
   In another embodiment, the invention provides a lock assembly for a door, the lock assembly including a latch assembly and chassis having a key cam operable in locking and unlocking the lock assembly, a door lever having a core cylinder with a key mechanism for locking and unlocking the lock assembly, a drive spindle that connects the door lever to the latch assembly, wherein rotation of the lever and spindle extends and retracts a latch, and a throw member positioned in the drive spindle, the throw member having a first and second hub positioned along a blade, wherein a first end of the throw member engages the core cylinder and a second end of the throw member engages the key cam, and wherein rotation of a key inside the key mechanism of the core cylinder is operable in rotating the throw member and key cam in retracting and extending the lock assembly. 
   Briefly summarized, the throw member of the invention provides manufacturers with an enhanced apparatus that couples a core cylinder having a key mechanism or key hole with a chassis having a key cam that locks and unlocks the lock assembly. Additionally, the throw member of the invention is accessible in the drive spindle and does not to come loose when the core cylinder or door lever is exchanged or modified. In further addition, the throw member of the invention prevents unauthorized removal of the door lever, and can be installed without using special tools or additional retaining mechanisms. 
   As is apparent from the above, it is an aspect of the invention to provide a lock assembly that includes a self-contained throw member. Other features and aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a partial cross-sectional view of a lock assembly embodying the invention. 
       FIG. 2  is a perspective view of a throw member embodying the invention. 
   

   DETAILED DESCRIPTION 
   Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. 
     FIG. 1  illustrates a partial cross-sectional view of a lock assembly  10  that includes a throw member  15  of the invention. A door lever (not shown) is connected to a drive spindle  22  that rotates to actuate a latch (not shown) of the lock assembly  10  between and an extended and a retracted position. The door lever includes a core cylinder  25  having a mechanism or key hole  30  for accepting a key  32  of a user in locking and unlocking the lock assembly  10 . The throw member  15  couples the core cylinder  25  with a key cam  35  of the chassis of the lock assembly  10  to lock and unlock the lock assembly  10 . 
     FIG. 2  shows a perspective view of the throw member  15  of the invention. The throw member  15  includes a blade  40  having a first end  42  and a second end  44 . The first end  42  of the blade  40  is designed to engage the key cam  35  of the chassis. The key cam  35  rotates to lock or unlock the lock assembly  10 . One embodiment of the blade  40  of the throw member  15  is generally square-shaped to engage the key cam  35  of the chassis. Another embodiment of the blade  40  can include a first end  42  that is narrowed to engage the key cam  35 . Of course, the shape and thickness of the blade  40  can vary to be compatible in engaging the key cam  35  and is not limiting on the invention. 
   The other or second end  44  of the blade  40  is integral with a first hub  45 . One embodiment of the first hub  45  is substantially cylindrical-shaped with a diameter to substantially fill the interior or cavity of the drive spindle  22 . Of course, the first hub  45  can include other shapes (e.g., square, triangular, octagonal, etc.) compatible to insert in the drive spindle  22  of the lock assembly  10 . The first hub  45  includes an extension  60  for engaging the core cylinder  25 . As shown in  FIG. 2 , one embodiment of the extension  60  includes a substantially asterisk shaped projection compatible for engaging the core cylinder  25 . Of course, the shape of the extension can vary with the type of receiving receptacle of the core cylinder  25 . In another embodiment, the first hub  45  can include a receptacle or cavity designed to receive an extension of the core cylinder  25 . 
   The throw member  15  also includes a second hub  50  spaced laterally along the blade  40  from the first hub  45 . One embodiment of the second hub  50  is substantially cylindrical-shaped similar to the first hub  45  described above. And like the first hub  45 , the second hub  50  has a diameter that substantially fills the interior or cavity of the drive spindle  22 . By filling the interior of the drive spindle  22 , the first  45  and second  50  hubs provide enhanced internal support to resist a crushing force applied by a vandal in an attempt to collapse the drive spindle  22  and remove the lever and/or core cylinder  25 . Thereby, the throw member  15  of the invention prevents unauthorized removal of the lever and core cylinder  25 . 
   The distance between the first  45  and second  50  hubs forms a channel  62  designed to receive a catch  65 . The catch  65  constrains the throw member  15  from moving laterally along the drive spindle  22 . Thereby, the throw member  15  does not come loose if the door lever and/or core cylinder  25  are removed or exchanged. Thus, the throw member  15  of the invention reduces the problem with components of the lock assembly  10  coming loose during shipment or the exchange of the door lever and/or core cylinder  25 . In one construction of the invention, the catch  65  constrains the door lever to the lock assembly as well as constrains the throw member  15  in the drive spindle  22 . When the throw member  15  is rotated, the notch  68  allows the catch  65  to be depressed such that the door lever can be removed or exchanged without releasing the throw member  15 . The shape (e.g., angular, square, etc.) and depth of the notch  68  can vary to receive the catch  65  and is not limiting on the invention. 
   The second hub  50  includes a passage or slot  70  for release from the catch  65 . During installation of the throw member  15  in the lock assembly  10 , the passage  70  enables the throw member  15  to be dropped in the drive cylinder  22  and rotated to allow the catch  65  to pass. Likewise, the throw member  15  can be readily removed by rotating the throw member  15  until the passage  70  in the second hub  50  aligns with the catch  65  to release the throw member  15 . Thereby, removal of the throw member  15  does not require any special tools. 
   As shown in  FIG. 1 , the throw member  15  is positioned in the drive spindle  22  of the lock assembly. The drive spindle  22  rotates to extend and retract the latch (not shown) of the lock assembly. The drive spindle  22  is designed with a portion removed to allow persons to access and rotate the throw member  15  while assembling or disassembling the lock assembly  10 . Yet, the drive spindle  22  is also designed to enclose the throw member  15  to provide enhanced protection from damage by vandals. A spring cage  72  encloses the drive spindle  22  against a door (not shown). 
   As noted above, the throw member  15  couples a core cylinder  25  with the key cam  35  in the chassis located in the bore of the door. One embodiment of the door lever and core cylinder  25  includes a key mechanism or key hole. One embodiment of the key mechanism includes a plurality of chambers  75  containing tumbler pins  77  that coordinate with a key  32  to enable the lock assembly  10  to be locked and unlocked. The tumbler pins  77  are positioned in accordance with the profile of the key  32 . If the profile of the key  32  matches the settings of the tumbler pins  77 , a user is allowed to rotate the key  32  and the key cam  35  of the chassis to unlock the lock assembly  10 . In one construction, the user can retract the latch without unlocking the lock assembly. The core cylinder  25  further includes a cap  80  that receives the extension of the throw member  15 . The extension of the throw member  15  can be designed to include a shape compatible with various types of caps for the core cylinders and is not limiting on the invention. 
   To remove the lever and core cylinder  25  requires a special extraction key  32  compatible with the positions of the tumbler pins  77 . In one embodiment, upon inserting the extraction key  32  in the key mechanism of the core cylinder  25 , one can rotate the key  32  toward a certain threshold angle of rotation such that a knob catch can be depressed and the lever and core cylinder  25  can be removed. In an alternative embodiment, the lever can include an exchangeable core cylinder  25  that can be withdrawn without removing the lever. To remove the exchangeable core cylinder  25 , an operator inserts the extraction key  32  in the key mechanism and rotates the core cylinder  25  toward a threshold angle for removal. Upon rotating the extraction key  32  and core cylinder  25  toward the threshold angle, the core cylinder  25  can be withdrawn and exchanged for another core cylinder  25 . Thereby, the core cylinder  25  can be exchanged without removing the lever or throw member  15 . Of course, other means can be used to exchange the core cylinder  25  and is not limiting on the invention. Removing the core cylinder  25  and/or door lever provides access to the throw member  15 . However, removing the core cylinder  25  or door lever does not release the throw member  15  or allow it to come loose. The throw member  15  is still retained in the drive spindle  22  by the catch  65  positioned between the first  45  and second  50  hubs. Thereby, the core cylinder  25  and/or door lever can be exchanged without causing other miscellaneous components of the lock assembly  10  to come loose. 
   Thus, the invention provides, among other things, an exemplary lock assembly having a self-contained throw member. Various features and advantages of the invention are set forth in the following claims.