Abstract:
A deadbolt mechanism including a lock out mechanism that functions to disable the operation of the deadbolt from at least one side of the deadbolt mechanism. The deadbolt mechanism includes a deadbolt, key cylinder, housing, turn knob and a shaft that connects the key cylinder and turn knob. To place the deadbolt mechanism in lock out mode, the turn knob is moved to the locked positioned and then pulled outward away from the door. By pulling the knob outward, the shaft engages a portion of the housing which prevents rotation of the shaft and thereby prevents movement of the deadbolt from the locked position.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Application Ser. No. 60/481,268 filed Aug. 20, 2003, the entire disclosure of which is hereby incorporated by reference. 
     
    
     BACKGROUND OF INVENTION  
       [0002]     This invention relates to locking devices in general and “lock-out” devices for deadbolts in particular.  
         [0003]     Bolts or deadbolts are well known devices for locking a door shut for security purposes. In such well-known arrangements, the deadbolt or bolt is mounted in the body of the door and the deadbolt is operated by mechanical operating devices mounted on either side of the door. When the deadbolt is operated to a locked position it typically extends or projects from the side of the door into an opening in the door jam or wall to which the door is mounted. Thus, the deadbolt when operated to an extended position, “bolts” or “locks” the door in a closed position. The mechanical operating devices also can operate to retract the bolt into the side of the door to unlock the deadbolt or bolt.  
         [0004]     In typical arrangements, one mechanical device used to operate a deadbolt may be a key cylinder into which a key is inserted. The key then can rotate the cylinder which, in turn, operates the deadbolt through various mechanical linkages. Another mechanical device that may be used to operate a deadbolt includes a knob that can be turned manually that, in turn, operates the deadbolt through various mechanical linkages.  
         [0005]     It is known to use a key cylinder and knob device together to operate deadbolts. The key cylinder is normally mounted on the exterior side of the door so that a user can use a unique key to operate and lock the deadbolt from the exterior side of the door. The manual knob is typically mounted on the interior of the door and operates the deadbolt from the interior side of the door without a key. Thus, the user can easily lock and unlock the deadbolt from the interior of the door without using or locating a key.  
         [0006]     It is sometimes desirable for users to disable the mechanical device for operating the deadbolt that is mounted on the exterior of the door. This can occur in situations in which the user does not wish to permit a person with a key to operate the deadbolt from the exterior side of the door such as, for example, a landlord/tenant situation in which the tenant does not wish the landlord to enter a rental property. Another important use of this feature is to prevent unauthorized access through the manipulation of the deadbolt by lock “picks” or the like. Mechanisms that disable the operation of a mechanical device used to operate a deadbolt are called “lock-out” devices.  
         [0007]     Known lock-out devices for deadbolts are unreliable, difficult and clumsy to use and have safety concerns in that they do not signal to a user when a “lock-out” mechanism is in operation.  
       SUMMARY OF INVENTION  
       [0008]     The invention provides a lock-out device for a locking mechanism that is reliable and simple to use and, in some embodiments, signals to the user that the lock-out mechanism has been activated. The invention may be comprised of a shaft upon which a knob or handle is mounted that has openings or channels in the wall of the shaft. The openings in the shaft correspond to protrusions or protuberances in the shaft housing. To operate the lock-out device, when the knob is turned to the locked position in which the deadbolt is extended, the handle or knob may be pulled which pulls the openings in the shaft into inter-locking engagement with the protrusions in the shaft housing. As a result, a mechanical member that operates the locking mechanism is restrained, thus “locking out” the deadbolt bolt mechanism. Thus, the deadbolt can not be operated by a key through a key cylinder mounted on the exterior side of the door effecting a “lock-out” condition. In some embodiments, when the shaft is pulled into a lock-out position, a portion of the shaft becomes visible from the interior-side of the door. In some embodiments the visible portion of the shaft includes an indicator or warning mechanism to signal to the user that the deadbolt is now in “lock-out” condition. 
     
    
     BRIEF DESCRIPTION OF DRAWINGS  
       [0009]     In the accompanying drawings, which are incorporated in and constitute a part of this specification, embodiments of the invention are illustrated, which, together with a general description of the invention given above, and the detailed description given below serve to illustrate the principles of this invention. The drawings and detailed description are not intended to and do not limit the scope of the invention or the claims in any way. Instead, the drawings and detailed description only describe embodiments of the invention and other embodiments of the invention not described are encompassed by the claims.  
         [0010]      FIG. 1  is a partial cross-sectional view of the deadbolt lockout mechanism of the present invention.  
         [0011]      FIG. 2  is a perspective view of the shaft used in the deadbolt lockout mechanism of the present invention.  
         [0012]      FIG. 3  is a side view of the shaft shown in  FIG. 2 .  
         [0013]      FIG. 4  in an end view of the shaft shown in  FIG. 2 .  
         [0014]      FIG. 5  is a side view of the shaft shown in  FIG. 2 , opposite from that shown in  FIG. 3 .  
         [0015]      FIG. 6  is a side view of the shaft shown in  FIG. 2 , opposite from that shown in  FIG. 4 .  
         [0016]      FIG. 7  is an exploded view of the shaft, mounting plate and knob subassembly of the deadbolt locking mechanism of the present invention.  
         [0017]      FIG. 8  is a plan view of the mounting plate shown in  FIG. 7 .  
         [0018]      FIG. 9  is a perspective view of the mounting plate shown in  FIG. 7 .  
         [0019]      FIG. 10  is a rear perspective view of the subassembly shown in  FIG. 7  in the lockout position.  
         [0020]      FIG. 11  is a front perspective view of the subassembly shown in  FIG. 7  in the lockout position.  
         [0021]      FIG. 12  is a side view of the subassembly shown in  FIG. 7  in the lockout position.  
         [0022]      FIG. 13  is a rear perspective view of the subassembly shown in  FIG. 7  in the operational deadbolt position.  
         [0023]      FIG. 14  is a front perspective view of the subassembly shown in  FIG. 7  in the operational deadbolt position.  
         [0024]      FIG. 15  is a side view of the subassembly shown in  FIG. 7  in the operational deadbolt position.  
         [0025]      FIG. 16  is an assembly view of the mounting plate and shaft subassembly in the lockout position.  
         [0026]      FIG. 17  is an assembly view of the mounting plate and shaft subassembly in the operational deadbolt position.  
         [0027]      FIG. 18  is a cross-sectional view of the mounting plate and shaft subassembly in lockout position.  
         [0028]      FIG. 19  illustrates a device for operating a locking device that can be operated through the use of a combination dial or a key cylinder. 
     
    
     DETAILED DESCRIPTION  
       [0029]     Referring now to  FIG. 1 , a door  2  including one embodiment of the invention is shown. As can be seen, a deadbolt manipulation mechanism, such as a conventional key cylinder  4  is mounted on one side of the door  2  which permits the deadbolt mechanism  3  to be operated by a key  5 . The key cylinder  4  is normally mounted on the exterior side  6  of the door  2  in a protective housing  7 . The “exterior-side” of a door is the side which is on the outside wall of a dwelling or building or any space desired to be “locked” from unauthorized entry. However, this invention is not limited to such a configuration and the key cylinder may be mounted on the interior or exterior side of the door. A second deadbolt manipulation mechanism, such as a knob or handle  8  also for operating the deadbolt is mounted on the side of the door opposite the key cylinder  4 . The knob or handle  8  is mounted on a shaft  10  further described below. The shaft  10  is, in turn, mounted in an opening  12  in a shaft housing  14 .  
         [0030]     The key cylinder  4  includes an elongated member  16  sometimes called a “tailpiece” that may be generally rectangular in cross-section, or may be adapted for other configurations. The elongated member  16  is connected to the rear of the key cylinder  4 . When the key cylinder  4  is rotated by key  5 , member  16  is also rotated. Member  16  is then connected by known mechanical linkages to a bolt or deadbolt (not shown). When member  16  is rotated in one direction the deadbolt is extended into a locked position. When member  16  is rotated in the opposite direction, the deadbolt is retracted into the door  2  into an unlocked position. This type of locking and unlocking action for a deadbolt through a key cylinder  4  is known.  
         [0031]     As can be seen in  FIG. 1 , shaft  10  is hollow in that it has a cavity  18  that extends along its entire length in a horizontal direction when shaft  10  is mounted in shaft housing  14 . Member  16  extends from key cylinder  4  into cavity  18  of shaft  10 . Thus, when knob  8  is rotated, shaft  10  rotates and then member  16  also rotates. Accordingly, the deadbolt can be operated through use of two different deadbolt manipulation mechanisms, such as handle  8  and key cylinder  4 . Thus, both handle  8  and key cylinder  4  may be used to operate the same deadbolt through the rotation of member  16 .  
         [0032]     Referring now to  FIGS. 2-6 , shaft  10  is shown. Shaft  10  is comprised of four different subsections along its length. The first subsection is the knob mounting portion  20 . Knob mounting portion  20  is generally rectangular or square in cross-section in one embodiment, but could be comprised of any cross-sectional shape. When shaft  10  is mounted in shaft housing  14 , knob mounting portion  20  extends from the exterior of shaft housing  14 . Knob  8  is then mounted on knob mounting portion  20  by fitting mounting portion  20  into a recess on knob  8 . Knob  8  is then secured to mounting portion  20  through the use of known connective methods, such as, for example, a set screw.  
         [0033]     The second portion of shaft  10  is signal portion  30 . Signal portion  30  is circular in cross-section in one embodiment, but similar to mounting portion  20 , its construction is not limited to any particular cross-sectional shape. Signal portion  30  has two boundary walls  3   2  that form a recessed area  3   4 . An indication mechanism, such as, for example, a colored, circular plastic clip  36  is snap-fit around shaft  10  to fit into recessed area  3   4  between walls  3   2 . An alternative indication mechanism is direct application of color to the signal portion  30  of the shaft  10 . The indication mechanism can be of any color, but a visually distinct color typically used to give alerts or signals such as red, orange or yellow should be used. Alternatively, other indication mechanisms can be used, such as, for example, engravings, knurling, demarcations, recesses, or other physical marking or add on portion that would provide a visible indication to the user that the shaft  10  was pulled-out and the deadbolt mechanism  3  was in lockout position. Optionally, other indication mechanisms could be used, including electronic mechanisms or audible mechanisms.  
         [0034]     The third portion of shaft  10  is camming portion  40 . Camming portion  40  has a cross-section that is not typical in that it is comprised of several cam surfaces  42 ,  44  and  46 . Camming portion  40  is essentially comprised of eight different sides. Four sides  47  of camming portion  40  are comprised of four camming surfaces  46 . The other four sides  48  are each comprised of two camming surfaces  42  and  44 . Sides  4   7  and sides  48  alternate around the circumference of camming portion  40 .  
         [0035]     The fourth subsection of shaft  10  is head portion  50 . Head portion  50  is generally circular in cross-section in one embodiment, but is not limited in any way to any particular cross-sectional shape. Head portion  50  has a diameter or cross-sectional width that is greater than any of the other three shaft portions  20 ,  30 ,  40  such that a ridge or lip  52  is formed between head portion  50  and camming portion  40 .  
         [0036]     Head portion  50  has two grooves, openings or depressions  54  in its otherwise generally circular perimeter.  
         [0037]     These depressions  54  are on opposite sides of head portion  50  and are parallel to the horizontal axis of the shaft lo when mounted in shaft housing  14 . Depressions  54  need not be of any particular shape, but in the embodiment shown in  FIGS. 2, 3  and  4  they are semi-circular in shape and form a groove-like depression. Depressions  54  could be located anywhere on head portion  50  in addition to the location shown in the embodiment depicted in  FIGS. 2-6 .  
         [0038]     Referring now to  FIGS. 7-9  shaft housing  14  is described. Shaft housing  14  is comprised of an outer decorative plate  60  and a mounting plate  62 . Both plates  60  and  62  have an opening  64  and  66 , respectively, for accommodating shaft  10 . Between plates  60  and  62  a signal disk  70  is mounted and is recessed from the surface of decorative plate  60 . Decorative plate  60  covers the exterior surface of mounting plate  62 .  
         [0039]     The interior or door facing side of mounting plate  62  includes a groove  80 . Groove  80  holds a spring or detent device  82 . Detent device  82  is a spring wire in the embodiment shown, but any type of known device that creates a spring, resilient or holding force can be used. The detent device  82  operates on cam surfaces  42  and  44  of shaft  10  as set forth below and serves to hold the shaft in, or urge it into, either a locked or unlocked position. The total shaft length can be of any dimension, but is preferably between 15 and 75 millimeters.  
         [0040]     The mounting plate  62  also includes a collar  84  that extends from plate  62  around opening  66  except where biasing device  82  is located. In the embodiment shown in  FIGS. 7-9 , collar  84  is circular or semi-circular in shape, but any shape that corresponds to the shape of head portion  50  of shaft  10  can be used. Collar  84  also has two protrusions or protuberances  86  that extend from the inside walls  83  of collar  84 . These protuberances  86  extend out from the wall of collar  84  approximately 2-3 millimeters to their tips and preferably can extend out from the inside walls of the collar anywhere from 1 millimeter to 2 centimeters. Protuberances  86  correspond to depressions  54  in shape and location, and, in this embodiment run parallel to the horizontal axis of shaft  10  when it is mounted in opening  66 .  
         [0041]     Now referring to  FIGS. 10-18 , the operation of one embodiment of the invention is described. As shown in FIG.  14 , the deadbolt mechanism  3  is in an unlocked position. As can be seen, head portion  50  extends beyond collar  84 . Thus, handle  8  can be rotated clockwise or counter clockwise to a locked position which would extend the deadbolt into a locked position. When handle  8  is rotated to the locked position, one of camming surfaces  46  operates against detent device  82  to “snap” the shaft  10  into the locked position.  
         [0042]     Referring now to  FIG. 10 , the shaft  10  is shown in the locked position. As can be seen, the depressions  54  correspond to and are “keyed” to protuberances  86  in the locked position. In this position, the deadbolt is extended from the door into the locked position.  
         [0043]     To operate the “lock-out” function the handle  8  is pulled outwardly from the door  2 . This causes detent device  82  to act against camming surface  42  so that an adequate pulling force must be applied to handle  8  to overcome the spring or resilient force against the cam surface  42 . This tends to prevent accidental operation of the “lock-out” function.  
         [0044]     As shaft  10  is pulled out by handle  8 , protuberances  86  fit into depressions  54  allowing the shaft  10  to continue to be pulled. When detent device  82  reaches the end of cam surface  42  it “snaps” or moves onto downward sloping cam surface  44 , effectively, pushing the head portion  50  into full interlocking engagement with the collar  84 , which is the “lock-out” position of the complete assembly.  
         [0045]     In this “lock-out” position, the protuberances  86  and the depressions  54  are in an interlocking relationship such that the deadbolt can not be operated by key cylinder  4  and key  5 . This is the result of member  16  being held stationary by engagement between the shaft  10  and housing  14 . The engagement of the shaft  10  with the housing  14  is a result of the head portion  50  of the shaft nesting within the collar  84  of the housing  14  with the depressions  54  engaging the protuberances  86  on the collar.  
         [0046]     In the lock-out position, the signal portion  30  of the shaft  10  and indication mechanism  36  becomes visible to the user indicating that the “lock-out” function is in operation and must be disengaged to operate the deadbolt. See  FIGS. 11-12 .  
         [0047]     To disengage the lock-out function, the user simply pushes on handle  8 . The same “snapping” camming surface operation will occur when the pushing force overcomes the spring force of detent device  82  on camming surface  44 . This will cause the lock-out function to disengage, thereby allowing handle  8  to be rotated which rotates member  16  and moves the deadbolt to the unlock position.  
         [0048]     In an alternate embodiment, a person ordinarily skilled in the art would understand that the depressions  54  could be present in the collar  84  and the corresponding protuberances  86  could be present in the head portion  50 . It should also be understood that deadbolt manipulation mechanisms are not limited simply to a key cylinder and handle, but may take the form of various mechanical devices, such as, for example a combination dial. Neither is the invention limited to deadbolts or bolts, but can be used with any known locking mechanism.  
         [0049]     The invention can be used with any mechanical device that can operate any locking mechanism, including a combination-type mechanical device or a device that can be operated by a combination dial or a key cylinder alternatively and interchangeably. In such a device, a user can operate a locking mechanism, including a deadbolt, by rotating a dial using an authorized numerical combination or by using the key cylinder. Such a device is depicted in  FIG. 19 .  
         [0050]     The invention has been described with reference to the preferred embodiment. Clearly, modifications and alterations will occur to others upon a reading and understanding of this specification. It is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.