Patent Publication Number: US-9890564-B2

Title: Interconnected lock with direct drive for adjustable deadbolt to latchbolt spacing

Description:
This application claims priority from U.S. patent application No. 62/069,477 filed on Oct. 28, 2014 and from U.S. patent application No. 62/084,699 filed on Nov. 26, 2014. 
    
    
     1. FIELD OF THE INVENTION 
     The present invention relates to interconnected locks, i.e., locks in which the outside of the door has a latchbolt lock mechanism on the bottom and a separate deadbolt lock mechanism on the top, but on the inside the mechanisms are interconnected so that rotating the inner handle automatically retracts both the latchbolt and the deadbolt, without having to separately unlock the two. 
     2. DESCRIPTION OF RELATED ART 
     Many local codes dictate when a deadbolt is in use the lockset must be an interconnected type lockset to allow simultaneous retraction of both the latchbolt and the deadbolt during egress from the inside of the door, i.e., the inside of the house or apartment, or the side of the door for which security is otherwise desired. Existing interconnect products have a fixed center to center distance measured from the center of rotation of the lever handle, where the latchbolt is positioned, to the centerline of the deadbolt. This fixed dimension of latchbolt/deadbolt axis spacing, or offset distance, is typically either 4 in. (102 mm) or 5.5 in. (140 mm) center to center. For new construction projects consumers can specify door preparation so the offset center-to center distance is not so much of an issue. There is a benefit to offering an adjustable interconnected lock for consumers on renovation and retro fit projects where the door is usually not replaced. There is typically a mix in the market place of 4 in. (102 mm) and 5.5 in. (140 mm) door preparations, but in interconnect markets the predominant door preparation is 4 in. (102 mm) as most competitive interconnects are 4 in. (102 mm). In non-interconnect markets the 5.5 in. (140 mm) distance is often used with a deadbolt and passage. The biggest driver for covering both preparations is to comply with the International Building Code (IBC). As more states adopt the IBC interconnected locks will increase in use as single handle motion egress is required. The ability to retrofit both offset distances without re-prepping or buying new doors would be advantageous. 
     SUMMARY OF THE INVENTION 
     Bearing in mind the problems and deficiencies of the prior art, it is therefore an object of the present invention to provide an interconnected lock which permits adjustment of deadbolt to latchbolt spacing. 
     It is another object of the present invention to provide an interconnected lock that is able to switch between different latchbolt-deadbolt offset spacings, and may optionally be re-handed, without adding or removing any components thereof. 
     A further object of the invention is to provide an interconnected lock that is able to accomplish the switch between different latchbolt-deadbolt spacings without the need for using any tools. 
     Still other objects and advantages of the invention will in part be obvious and will in part be apparent from the specification. 
     The above and other objects, which will be apparent to those skilled in the art, are achieved in the present invention which is directed to an interconnected lock for use on a door, where the lock has adjustable offset spacing between a deadbolt and latchbolt. The lock includes a latchbolt mechanism mountable in a first bore through a door and including a latchbolt and an interior actuator operable to move the latchbolt between latched and unlatched positions along a first axis. The lock also includes a deadbolt lock mechanism mountable in a second bore through a door, with the second bore being spaced from the first bore, and has a deadbolt moveable by the deadbolt lock mechanism along a second axis between latched and unlatched positions. The distance between the latchbolt first axis and the deadbolt second axis is the offset spacing. The lock further includes first and second shafts for actuating the deadbolt lock mechanism. The first shaft is disposed at a first offset spacing from the latchbolt first axis and the second shaft is disposed at a second, greater offset spacing from the latchbolt first axis. 
     The lock additionally includes a driver member connected to and moveable by the latchbolt actuator, the driver member being alternately connectable to rotate either the first deadbolt-actuating shaft or the second deadbolt-actuating shaft, depending on the offset spacing between the latchbolt first axis and the deadbolt second axis. The driver member may be a linkage arm having a lower end connected to and moveable by the latchbolt actuator. The linkage arm has a length extending upwards with first and second upper positions. The first upper linkage arm position has a distance from the lower end sufficient for connection to rotate the first deadbolt-actuating shaft. The second upper linkage arm position has a distance from the lower end sufficient for connection to rotate the second deadbolt-actuating shaft. The first and second upper linkage arm positions are alternately connectable to rotate the first and second deadbolt-actuating shafts, and thereby actuate the deadbolt lock mechanism, depending on the offset spacing between the latchbolt first axis and the deadbolt second axis. 
     Upon operation of the interior actuator, the linkage arm moves the deadbolt along the second axis from the latched to the unlatched position at the same time that the operation of the interior actuator moves the latchbolt along the first axis from the latched to the unlatched position. The first and second upper linkage arm positions are alternately connectable to rotate the first and second deadbolt-actuating shafts when adjusting or changing spacing between the first and second axes to adjust or change offset spacing between the deadbolt and latchbolt between a first distance and a second, longer distance. 
     The lock may include a rotatable lower cam operable by the interior actuator, with the lower cam having a pair of arms extending outward on opposite sides thereof. The lock may also include a sliding mechanism that is urged upward by one of the lower cam arms when the interior actuator is rotated. The linkage arm may be urged upward by a lower slider portion of the sliding mechanism to rotate the first or second deadbolt-actuating shafts. An upper slider portion of the sliding mechanism may be connected to the lower slider, and the linkage arm lower end may be connected to the upper slider and extend upward therefrom. The linkage arm lower end may be connected by a pin to the upper slider. 
     The lock may include first and second upper cam plates, with the first upper cam plate being connected to the first deadbolt-actuating shaft, and the second upper cam plate being connected to the second deadbolt-actuating shaft. The first and second upper linkage arm positions are alternately connectable to the first and second upper cam plates. 
     The first upper linkage arm position may be connectable to the first upper cam plate by a pin, and the second upper linkage arm position may be connectable to the second upper cam plate by a pin. When the deadbolt is at the first offset spacing, the first upper linkage arm position is connected to the first upper cam plate and the second upper pin position of the linkage is unconnected to the second upper cam plate; when the deadbolt is at the second offset spacing, the second upper linkage arm position is connected to the second upper cam plate and the first upper pin position of the linkage is unconnected to the first upper cam plate. The pins may be located on the cam plates or the linkage arm upper arm positions. The first and second upper linkage arm positions may be alternately connectable to rotate the first and second deadbolt-actuating shafts without adding or removing any components thereof, and without any use of tools. 
     In another aspect the present invention is directed to a method of adjusting offset spacing between a deadbolt and latchbolt in interconnected lock for use on a door. The method comprises initially providing an interconnected lock of the type described above. If adjusting or changing to a shorter offset spacing distance, the method comprises connecting the first upper linkage arm position to rotate the first deadbolt-actuating shaft and thereby actuate the deadbolt lock mechanism. If adjusting or changing to a longer offset spacing distance, the method comprises connecting the second upper linkage arm position to rotate the second deadbolt-actuating shaft and thereby actuate the deadbolt lock mechanism. The connection of the first and second upper linkage arm positions is accomplished without adding or removing any components thereof. 
     Yet another aspect of the invention is directed to a method of re-handing or reversing an interconnected lock for use on a door. The method initially comprises providing an interconnected lock of the type described above, wherein the lock further includes first and second upper cam plates. The first upper cam plate is connected to the first deadbolt-actuating shaft, and the second upper cam plate is connected to the second deadbolt-actuating shaft. The first and second upper linkage arm positions are alternately connectable to the first and second upper cam plates. If handing the lock for a right hand operation, the method comprises connecting the linkage arm to one side of the first and second upper cam plates. If handing the lock for a left hand operation, the method comprises connecting the linkage arm to the other side of the first and second upper cam plates. 
     The first and second upper linkage arm positions may be alternately connectable to the first and second upper cam plates by pins located on either side thereof. If handing the lock for a right hand operation, the linkage arm is connected to a pin on one side of the first and second upper cam plates. If handing the lock for a left hand operation, the linkage arm is connected to a pin on the other side of the first and second upper cam plates. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The features of the invention believed to be novel and the elements characteristic of the invention are set forth with particularity in the appended claims. The figures are for illustration purposes only and are not drawn to scale. The invention itself, however, both as to organization and method of operation, may best be understood by reference to the detailed description which follows taken in conjunction with the accompanying drawings in which: 
         FIG. 1  is an exploded perspective view of an embodiment of the interconnected lock of the present invention for mounting and use on the inside of a door. 
         FIG. 2  is an exploded perspective view of an embodiment of the interconnected lock of the present invention for a mechanical lock assembly. 
         FIG. 3  is an exploded perspective view of an embodiment of the interconnected lock of the present invention for an electromechanical lock assembly. 
         FIG. 4  is a rear perspective, partially exploded view of an embodiment of the interconnected lock of the present invention showing the working components in connection with a deadbolt and a latchbolt. 
         FIG. 5  is a rear perspective, partially exploded view of an embodiment of the interconnected lock of the present invention showing the set up for a latchbolt/deadbolt axis spacing, or offset distance, is at a smaller distance, for example, 4 in. (102 mm) center to center. 
         FIG. 6  is a rear perspective, partially exploded view of an embodiment of the interconnected lock of the present invention showing the set up for a latchbolt/deadbolt axis spacing, or offset distance, is at a larger distance, for example, 5.5 in. (140 mm) center to center. 
         FIG. 7  is a front perspective, partially exploded view of an embodiment of the front cover plate or escutcheon for enclosing the interconnected lock of the present invention showing the reversing thumbturn and deadbolt cover plate for different latchbolt/deadbolt axis spacings. 
         FIG. 8  is a rear perspective view of the reversing thumbturn and deadbolt cover plate of  FIG. 7 . 
         FIG. 9  is a front view of an embodiment of the escutcheon for enclosing an electromechanical lock assembly on the inside of the door in which the latchbolt/deadbolt axis spacing, or offset distance, is at a smaller distance, for example, 4 in. (102 mm) center to center. 
         FIG. 10  is a rear perspective, partially exploded view of the escutcheon and electromechanical lock module of  FIG. 9 . 
         FIG. 11  is a front view of an embodiment of the escutcheon for enclosing an electromechanical lock assembly on the inside of the door in which the latchbolt/deadbolt axis spacing, or offset distance, is at a larger distance, for example, 5.5 in. (140 mm) center to center. 
         FIG. 12  is a rear perspective, partially exploded view of the escutcheon and electromechanical lock module of  FIG. 11 . 
         FIG. 13  is a rear perspective, partially exploded view of the interconnected lock of the present invention showing the removable upper cover for easily changing handing of the lock mechanism. 
         FIG. 14  is a rear perspective sectioned view of the lower portion of the interconnected lock of the present invention showing the guiding channels under the lower cover and the upper and lower sliders. 
         FIG. 15  is a rear perspective view of the interconnected lock of the present invention set up for a 5.5 in. (140 mm) latchbolt/deadbolt axis spacing and a right-hand door installation. 
         FIG. 16  is a rear perspective view of the interconnected lock of the present invention set up for a 5.5 in. (140 mm) latchbolt/deadbolt axis spacing and a left-hand door installation. 
         FIG. 17  is a front perspective, partially exploded view of the thumbturn and deadbolt cover plate installation on the escutcheon of the interconnected lock of  FIGS. 15 and 16 . 
         FIG. 18  is a rear perspective view of the interconnected lock of the present invention showing the lower, latchbolt cam plate and lower slider mechanisms. 
         FIG. 19  is a rear perspective view of the interconnected lock of the present invention showing the upper, deadbolt cam plates and upper slider mechanisms. 
     
    
    
     DESCRIPTION OF THE EMBODIMENT(S) 
     In describing the embodiment(s) of the present invention, reference will be made herein to  FIGS. 1-19  of the drawings in which like numerals refer to like features of the invention. 
     As shown by an embodiment in the drawings, the interconnected lock  20  of the present invention is mounted and for use on the inside of a door  21  ( FIG. 1 ), where the lock has adjustable offset spacing between a deadbolt  50  and latchbolt  30  extending from door edge  21   a . A front cover plate or escutcheon  22  encloses the lock assembly  20  over back plate  150  disposed on the inside surface of the door. The interconnected lock includes a latchbolt mechanism  32  mountable in a first bore  34  through the door  21 . The latchbolt lock mechanism  32  includes a latchbolt  30  and a manually operated interior actuator or lever  36 , here a handle extending laterally from and rotatable about latchbolt actuator driver or shaft  44 , operable to move the latchbolt  30  between latched and unlatched positions along a first axis  42 . The interconnected lock further includes a deadbolt lock mechanism  52  mountable in a second bore  54  through a door, where the second (deadbolt) bore  54  is spaced from the first (latchbolt) bore  34 . The deadbolt lock mechanism  52  includes a deadbolt  50  moveable by the deadbolt lock mechanism  52  along the second axis  56  between latched and unlatched positions, with distance between the latchbolt first axis  42  and the deadbolt second axis  56  being the offset spacing  70 . Deadbolt actuator or thumbturn  68  on deadbolt cover plate  29  is rotatable about deadbolt actuator driver or shaft  69  to cause deadbolt mechanism to latch and unlatch deadbolt  50  manually from the inside of the door. As part of the adjustment of lock assembly  20  to the different latchbolt-deadbolt offset distances, thumbturn  68  and shaft  69  are removed from the lock assembly, and deadbolt cover plate  29  may be rotated 180 degrees as shown by arrow  79  ( FIG. 7 ) to align the deadbolt actuator shaft opening to the desired offset position of the deadbolt  50  and deadbolt mechanism  52  before mounting on escutcheon  22 . Cover plate  29  then covers the opening  28   a  or  28   b  for deadbolt actuator shaft  69  which is not in use. A fixed tab  27  ( FIGS. 5, 6, 8 and 17 ) on the inside of cover plate  29  engages the cam plate not in use through the escutcheon opening  28   a  or  28   b , and locks the unused idle cam plate and associated shaft against rotation so that pins  114   a ,  114   b  (on cam plate  110 ) or pins  124   a ,  124   b  (on cam plate  120 ) are oriented in a position, e.g., vertically aligned, and do not interfere with movement of the driver member or linkage arm  90 . 
     The interconnected lock  20  also includes a rotatable lower cam plate connected to latchbolt actuator driver or shaft  44  and operable by the interior actuator, the lower cam having a pair of arms  46   a ,  46   b  ( FIG. 4 ) extending outward on opposite sides thereof. Shaft  44  extends beyond cam plate  46  and engages an otherwise conventional latchbolt lock core (not shown) positioned in bore  34 , such as a cylindrical or tubular lock, to move latchbolt  30  between its latched and unlatched positions upon rotation of the inner latchbolt actuator. When inner handle  36  is horizontal and latchbolt actuator shaft  44  is in its default position, latchbolt  30  is in its unretracted, latched position, and when inner handle  36  is rotated, latchbolt  30  moves inward to its retracted, unlatched position. 
     Slider or sliding mechanism  80  forms part of the mechanism that translates rotation of the latchbolt actuator  36  to retract the deadbolt  50 , and comprises lower and upper sliders  82 ,  84 , respectively. Lower slider or sliding mechanism  82  is urged upward by one of the lower cam arms  46   a  or  46   b  when the interior actuator  36  is rotated. As shown in  FIG. 18 , the lower edges  82   a ,  82   b  of the lower slider contacted by the lower cam arms  46   a ,  46   b , respectively, are angled from horizontal in the configuration of a shallow “V” so that the edge extends upward from the centerline to each opposite side edge of the lower slider at an acute angle greater than zero, with respect to horizontal. The rotational sliding contact of the lower cam arms  46   a  or  46   b  against the angled lower edges  82   a ,  82   b , respectively, maximizes the linear travel distance of the lower slider, and increases the output driving torque of the deadbolt driver shaft which is ultimately rotated as described below. Springs  83   a ,  83   b  aligned on either side of a vertical center line are captured between slots  23   a ,  23   b  on the inside of the escutcheon  22  and the lower slider  82 . Tabs extending inward from lower slider  82  engage and compress springs  83   a ,  83   b  as lower cam arms  46   a  or  46   b  move the lower slider upward, and the action of the springs urges the lower slider downward when force is removed from the actuator. Upper slider or sliding mechanism  84  is connected to the lower slider at an upper midpoint region. A driver member or linkage arm  90  is removably connected at a lower end  91  by a pin  86  on the upper slider and extends upward therefrom. 
     The interconnected lock further includes a pair of upper cam plates, one upper cam plate  110  positioned at a first location, e.g., 4 in. (102 mm) from the latchbolt first axis, and the other upper cam plate  120  positioned at a second location, e.g., 5.5 in. (140 mm) from the latchbolt first axis. The first upper cam plate is disposed to be operably connected to the deadbolt lock mechanism  52  by driver or shaft  112  extending therefrom when it is at the first offset distance, e.g., 4 in. (102 mm) from the latchbolt first axis  42  ( FIG. 5 ), and the second upper cam plate is disposed to be operably connected to the deadbolt lock mechanism  52  by driver or shaft  122  extending therefrom when it is at the second offset distance, e.g., 5.5 in. (140 mm) from the latchbolt first axis  42  ( FIG. 6 ). 
     Deadbolt lock mechanism  52  includes a deadbolt actuator shaft extending from an interior thumbturn  68  through an opening and locking into deadbolt cam plate  110  or  120 , depending on the offset distance. Deadbolt bore  54  extends perpendicularly from the inner surface of door  21  to its outer surface ( FIG. 1 ). Deadbolt lock drivers or shafts  112  and  122  extend beyond their respective cam plates  110  and  120  ( FIGS. 4, 5 and 6 ) to engage an otherwise conventional security lock (not shown) in bore  54  operated by a key on the outside of the door or thumbturn on the inside of the door to move deadbolt  50  between its latched and unlatched positions upon rotation of the deadbolt actuator shaft. 
     The linkage arm  90  has a length extending upwards from the upper slider  84  and two upper positions  92 ,  94  for alternate pin connection to the upper cam plates ( FIGS. 5, 6 and 19 ). Linkage arm  90  is generally curved to be disposed on one side or another of vertically aligned upper cam plate shafts  112 ,  122 , with upper positions  92 ,  94  extending toward a vertical center line of the escutcheon. First upper position  92  is midway along the linkage length and second upper position  94  is at the upper end of the linkage length. To move the deadbolt  50  along the second axis  56   a  from the latched to the unlatched position when it is at the first offset distance, e.g., 4 in. (102 mm) from the latchbolt first axis  42 , an opening  93  in the first linkage upper position  92  may be removably connected to the first upper cam plate  110  by pin  114   a  or  114   b  ( FIG. 5 ) at a location on the cam plate  110  a distance from the second axis  56   a , to rotate the cam plate  110  as the upper slider  84  is urged upward by the lower slider  82  and lower cam arm  46   a  or  46   b  during rotation of the interior actuator or lever  36 . When operating the deadbolt  50  at the first offset spacing, the second upper pin position  94  of the linkage  90  is unconnected to the second upper cam plate  120 . 
     To move the deadbolt  50  along the second axis  56   b  from the latched to the unlatched position when it is at the second offset distance, e.g., 5.5 in. (140 mm) from the latchbolt first axis  42 , an opening  95  in the second linkage upper position  94  may be removably connected to the second upper cam plate  120  by a pin  124   a  or  124   b  ( FIG. 6 ) at a location on the cam plate  120  a distance from the second axis  56   b , to rotate the cam plate  120  as the upper slider  84  is urged upward by the lower slider  82  and lower cam arm  46   a  or  46   b  during rotation of the interior actuator or lever  36 . When operating the deadbolt  50  at the second offset spacing, the first upper pin position  92  of the linkage  90  is unconnected to the first upper cam plate  110 . 
     Regardless of the offset spacing between the deadbolt and latchbolt, rotating the inner handle  36  moves the linkage arm  90  upwards, rotating the upper cam plate  110  or  120  operably connected to the deadbolt lock mechanism  52  and automatically retracts both the latchbolt  30  and the deadbolt  50 , without having to separately unlock the two. At this point, the user may open the door. After the user is outside and the door is closed, the latchbolt  30  normally returns to the latched position automatically, and the deadbolt  50  may be manually latched by use of a key on an exterior deadbolt security lock  58  or whatever security locking mechanism is employed. It should be noted that operation of the handle  38  on the outer side of the door does not rotate latchbolt cam plate  46 , and the deadbolt  50  may only be retracted from the outside of the door by the key or otherwise unlocking the deadbolt security locking mechanism. 
     To provide for easy installation, the slider mechanism  80 , linkage  90  and cam plates  110 ,  120  are mounted inside the front wall of escutcheon  22 , and lower and upper cover plates  140  and  144 , respectively are provided thereover. As shown by way of example in  FIG. 13 , lower cover plate  140  is substantially flat and is securely mounted inside the escutcheon, and is not intended to be removed for offset adjustment or re-handing. Side channels  141   a ,  141   b  shown in  FIG. 14  are formed between the escutcheon and the edges of substantially flat lower cover plate  140  to guide the sliding of the edges of lower slider  82  upward and downward, and upward facing tabs  142   a ,  142   b  are provided at the opposite sides of the upper end to retain the edges  145   a ,  145   b , respectively, of the arms extending laterally on upper cover plate  144 . Upper cover plate  144  is intended to be removably secured by screw fasteners through openings  147   a ,  147   b  ( FIG. 13 ) in the lateral arms, so that linkage arm  90  may be accessed and set as needed for offset adjustment or re-handing. Upper cover plate  144  includes central openings  146   a ,  146   b  which align with and serve as bearing journals to support rotation of upper cam plate shafts  112 ,  122 , respectively. A vertically aligned slot  148  guides upward and downward movement of pin  86  holding upper slider  84 . 
     To re-hand or reverse the lock mechanism from right-handed operation to left-handed operation, and vice-versa, the symmetry of the upper slider  84  and upper cam plates  110  and  120  about a central vertical line enables the linkage arm  90  to be easily flipped from one side to the other, as shown by way of example in  FIGS. 15 and 16 . Using a wider 5.5 in. (140 mm) offset as an example, in a right hand configuration linkage arm lower end  91  is connected to upper slider pin  86 , and linkage arm second upper position opening  95  is connected to second upper cam plate pin  124   a . First upper cam plate  110  at the 4 in. (102 mm) offset is the idle cam, and is locked by tab  27  ( FIG. 17 ) with the pins  114   a ,  114   b  vertically aligned on the side of shaft  112  opposite linkage arm  90 , with linkage arm first upper position opening  93  unconnected. To change to the left hand configuration, linkage arm  90  is removed from pins  86  and  124   a , and flipped around to the other side of shafts  112 ,  122 , and linkage arm lower end  91  is again connected to upper slider pin  86 . Linkage arm second upper position opening  95  is then connected to the opposite second upper cam plate pin  124   b . The idle first upper cam plate  110  rotated 180 degrees and again locked by tab  27  with the pins  114   a ,  114   b  vertically aligned on the side of shaft  112  opposite linkage arm  90 . If the 4 in. (102 mm) offset is desired, pins  114   a  (right hand) and  114   b  (left hand) are similarly connected to linkage arm first upper position opening  93 . Upper cam plate  120  becomes the idle cam, and is oriented with pins  124   a ,  124   b  aligned vertically opposite the linkage arm, and linkage arm second upper position opening  95  unconnected. Escutcheon openings  28   a ,  28   b  are marked with indicia to indicate right or left hand installation. Other than removing upper cover  144 , no tools are required for the re-handing. 
     The interconnected lock of the present invention permits an electromechanical lock module  130  ( FIGS. 3 and 9-12 ) to be mounted on the escutcheon  22  to engage through openings  28   a  or  28   b  the first or second upper cam plate in use for the desired offset to control the remote latching or unlatching of the deadbolt.  FIGS. 9 and 10  show an example of the electromechanical lock module  130  engaging the lower opening  28   a  for the smaller latchbolt/deadbolt offset and  FIGS. 11 and 12  show the electromechanical lock module engaging the upper opening  28   b  for the larger latchbolt/deadbolt offset. 
     Accordingly, the present invention provides an interconnected lock that is able to switch between different latchbolt-deadbolt offset spacings without adding or removing any components thereof. The interconnected lock of the invention may be switched between different latchbolt-deadbolt offset spacings without the potential of losing parts during the spacing adjustment. Additionally, the interconnected lock of the present invention is able to accomplish the switch between different latchbolt-deadbolt spacings without the need for using any tools. The linkage arm adjustment design configuration is an ergonomic and intuitively adjustable solution for the installer and cost effective for the manufacturer. Since no disassembly is required, installation time is reduced. 
     While the present invention has been particularly described, in conjunction with a specific preferred embodiment, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. It is therefore contemplated that the appended claims will embrace any such alternatives, modifications and variations as falling within the true scope and spirit of the present invention.