Patent Publication Number: US-10767389-B2

Title: Bridge adapter

Description:
FIELD OF INVENTION 
     The present invention relates generally to lock accessories, and more specifically to adapters for supporting mortise locks. 
     BACKGROUND 
     Mortise locks are widely used for commercial and residential applications. A mortise lock, unlike a cylinder lock, is installed in a cavity cut or defined within the door stile (a cylinder lock is installed in a hole cut through the door). After installation, the mortise lock body is contained completely in the cavity. Since the body size of a mortise lock is not standardized, the pre-cut or previously used cavity may not be properly sized to match a particular mortise lock. This is particularly true when locks are modernized or updated thus complicating lock installation. 
     In addition, in some installations, a user may desire to eliminate the mortise lock altogether and replace the mortise lock with a faceplate. In general, a faceplate must present a smooth surface along the door stile. Unfortunately, doors that previously included a mortise lock may lack a surface to which to attach the faceplate. In those instances, expensive replacement doors may be necessary. 
     As such bridge adapters are presented herein. 
     SUMMARY 
     The following presents a simplified summary of some embodiments of the invention in order to provide a basic understanding of the invention. This summary is not an extensive overview of the invention. It is not intended to identify key/critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some embodiments of the invention in a simplified form as a prelude to the more detailed description that is presented below. 
     As such, bridge adapters configured for insertion into a cavity within a door stile are presented, the bridge adapter including: a planar body including, a top plate disposed along a distal end of the planar body, where the top plate includes a top plate front edge disposed along the distal end and a top plate back edge located opposite the top plate front edge, where the top plate further includes at least one raised feature along a top surface of the top plate, and where the top plate front edge includes a locking indent sized to couple with the raised locking feature, a first side plate including a first side plate front edge and a first side plate back edge located opposite the first side plate front edge, where the first side plate is mechanically coupled along the first side plate front edge and the top plate back edge by a first hinge, a bottom plate including a bottom plate front edge and a bottom plate back edge located opposite a bottom plate front edge, where the bottom plate front edge is mechanically coupled along the first side plate back edge and the bottom plate front edge by a second hinge, where the bottom plate includes at least one through hole sized to receive the at least one raised feature, and a second side plate including a second side plate front edge and a second side plate back edge located opposite the second side plate front edge, where the second side plate front edge is mechanically coupled along the bottom plate back edge and the second side plate front edge by a third hinge; and a tail including a first end and a second end, where the tail is mechanically and removably coupled along the second side plate back edge and the first end, where the tail further includes a raised locking feature, the locking feature disposed along the first end. In some embodiments, the planar body and the tail are made of a polymeric material and where the first hinge, second hinge, and third hinge are living hinges. In some embodiments, at least one plate includes at least one support rib disposed along an inner surface of the at least one plate. In some embodiments, the tail further includes a handle disposed along the second end. In some embodiments, the handle is curved. In some embodiments, the tail is flexible. In some embodiments, the tail is connected to the second side back edge by a perforated feature for detaching the tail. In some embodiments, the first hinge and second hinge have a range of motion of more than approximately 90 degrees and where the third hinge has a range of motion of at least approximately 120 degrees. In some embodiments, the third hinge has a range of motion of at least approximately 130 degrees. In some embodiments, the bottom plate is substantially the same width as the cavity, where at least one of the first side plate and the second side plate includes a friction-enhancing feature for engaging a wall of the cavity, and where the friction enhancing feature is raised and disposed along an outer surface of the bottom plate. In some embodiments, the second side plate includes a cutout sized to enable a tail to pass around the bridge adapter, where the cutout is disposed along an outer surface of the second side plate. In some embodiments, the top plate further includes a through hole centered with the top plate. 
     In other embodiments, methods of installing a first bridge adapter in a cavity are presented including: providing the first bridge adapter, where the first bridge adapter includes: a planar body including, a top plate disposed along a distal end of the planar body, where the top plate includes a top plate front edge disposed along the distal end and a top plate back edge located opposite the top plate front edge, where the top plate further includes at least one raised feature along a top surface of the top plate, and where the top plate front edge includes a locking indent, a first side plate including a first side plate front edge and a first side plate back edge located opposite the first side plate front edge, where the first side plate is mechanically coupled along the first side plate front edge and the top plate back edge by a first hinge, a bottom plate including a bottom plate front edge and a bottom plate back edge located opposite a bottom plate front edge, where the bottom plate front edge is mechanically coupled along the first side plate back edge and the bottom plate front edge by a second hinge, where the bottom plate includes at least one through hole sized to receive the at least one raised feature, and a second side plate including a second side plate front edge and a second side plate back edge located opposite the second side plate front edge, where the second side plate front edge is mechanically coupled along the bottom plate back edge and the second side plate front edge by a third hinge; and a tail including a first end and a second end, where the tail is mechanically and removably coupled along the second side plate back edge and the first end, where the tail further includes a raised locking feature sized to couple with the locking indent, the locking feature disposed along the first end; inserting the first bridge adapter into the cavity through the opening; bending the second hinge and third hinge of the first bridge adapter in such a way that the first side plate is in contact with a first wall of the cavity, the bottom plate is in contact with the bottom of the cavity, and the second side plate is in contact with a second wall of the cavity; and bending the first hinge of the first bridge adapter such that the locking indent engages with the raised locking feature. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which: 
         FIGS. 1A-1C  are illustrative representations of various views of a bridge adapter in accordance with embodiments of the present invention; 
         FIGS. 2A-2D  are illustrative representations of side views of a bridge adapter in accordance with embodiments of the present invention in the process of folding; 
         FIGS. 3A-3C  are illustrative representations of cross-sectional views of a method for installing a bridge adapter in accordance with embodiments of the present invention; 
         FIGS. 4A-4C  are illustrative representations of cross-sectional views of a method for installing two bridge adapters in accordance with embodiments of the present invention; 
         FIG. 5  is an illustrative representation an installed bridge adapter and bridge in accordance with embodiments; and 
         FIG. 6  is an illustrative representation of two installed bridge adapters and bridge in accordance with embodiments of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     The present invention will now be described in detail with reference to a few embodiments thereof as illustrated in the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art, that the present invention may be practiced without some or all of these specific details. In other instances, well known process steps and/or structures have not been described in detail in order to not unnecessarily obscure the present invention. 
     For purposes of the present disclosure, a “bridge adapter” is a spacer that can support a snap-in bridge that, in turn, may support a mortise lock or a faceplate. A “cavity” is a hollow space within a door stile. An “opening” is the opening to the cavity located on the surface of the door stile. 
     An object of the present invention is to provide a bridge adapter that can support a bridge which supports the body of a mortise lock or faceplate in a cavity that is too deep for the body of the mortise lock. 
     Another object of the present invention is to provide a bridge adapter that can be inserted into a cavity within the door stile, even when the opening of the cavity is smaller than the cavity itself. 
     One embodiment of the bridge adapter of the present invention is a body that, when folded, becomes a rectangular tube-shaped spacer that is strong enough to support the body of a mortise lock or faceplate. In embodiments, a tail coupled with the body may be used for insertion of the body into a door stile cavity. The body folds into the desired rectangular tube shape as it is pushed into the cavity. 
       FIG. 1  is an illustrative representation of various views of a bridge adapter in accordance with embodiments of the present invention. In particular, as illustrated in  FIGS. 1A to 1C , bridge adapter  100  may include planar body  102  which may further include a number of features. For example, planar body  102  may include top plate  110 , that is disposed along distal edge of planar body  102 . Top plate  110  may be defined by top plate front edge as indicated by dashed line  114  disposed along a distal end and top plate back edge as indicated by dashed line  124  disposed opposite top plate front edge. The illustrated dashed lines are for clarity in defining the various plates presented across all views. Further illustrated are raised features  116 A and  116 B. Raised features  116 A and  116 B may be useful in stacking bridge adapter embodiments as will be discussed in further detail below for  FIG. 4 . In addition, top plate  110  may include a through hole  118 , which may be smooth bore or threaded and centered with the top plate in embodiments. Still further illustrated is locking indent  119  sized to couple with raised locking feature  107 . 
     Planar body  102  may additionally include first side plate  120 , located proximally to top plate  110 . First side plate  120  may be defined by the first side plate front edge as indicated by dashed line  124  disposed along a distal end and the first side plate back edge as indicated by  134  disposed opposite the first side plate front edge. The first side plate front edge may be connected with the top plate back edge by first hinge  152 . In embodiments, first hinge  152  may have a range of motion of more than approximately 90 degrees. In one embodiment, a range of motion of the first hinge is approximately 93 degrees. First hinge  152  is preferably strong and capable of flexing without damage. In one embodiment, the first hinge is a living hinge. As known in the art, a living hinge is a thin flexible hinge (flexure bearing) made from the same material as the two rigid pieces it connects, rather than cloth, leather, or some other flexible substance. A living hinge is typically thinned, cut, or formed to allow the rigid pieces to bend along the line of the hinge. First side plate  120  may also include friction-enhancing features  122  which may assist in retaining the bridge adapter in the cavity by engaging with the walls of the cavity. In an embodiment, as illustrated in  FIG. 1A , friction-enhancing feature  122  includes two raised bumps that may engage with the inner surface of the cavity. In some instances, the inner surface of the cavity may be irregular. Friction-enhancing raised feature embodiments may be useful to provide a secure mechanical connection with irregular or non-planar surfaces. Further illustrated is cutout  126  sized to enable a tail to pass around bridge adapter  100  when installed. In embodiments, cutout  126  may be disposed along an outer surface of second side plate  102 . Cutout embodiments will be discussed in further detail below for  FIG. 4 . 
     Planar body  102  may also include bottom plate  130 , located proximally to first side plate  120 . Bottom plate  130  may be defined by bottom plate front edge as indicated by dashed line  134  disposed along a distal end and bottom plate back edge as indicated by dashed line  144  disposed opposite the bottom plate front edge. In an embodiment, a length from the bottom plate front edge to the bottom plate back edge may be substantially the same as a length from the top plate front edge to the top plate back edge. The bottom plate front edge may be connected with the first side plate back edge by second hinge  154 . Second hinge  154  may have a range of motion of more than approximately 90 degrees. In one embodiment, the range of motion is approximately 93 degrees. Second hinge  154  is preferably strong and capable of flexing without damage. In an embodiment, the second hinge is a living hinge. Bottom plate  130  preferably also includes through holes  132 A and  132 B. The through holes may be arranged to engage with raised features  116 A and  116 B when two bridge adapter embodiments are stacked on top of each other within a cavity. Stacking is further elucidated below with respect to  FIG. 4 . 
     Planar body  102  may further include second side plate  140 , located proximally to bottom plate  130 . Second side plate  140  may be defined by second side plate front edge as indicated by dashed line  144  disposed along a distal end and second side plate back edge as indicated by dashed line  154  disposed opposite the second side plate front edge. The length from the second side plate front edge to the second side plate back edge is preferably the same as the length from the first side plate front edge to the first side plate back edge. The second side plate front edge may be mechanically coupled with the bottom plate back edge by third hinge  156 . Third hinge  156  may be different from the first and second hinges in having a wider range of motion. In embodiments, third hinge may have a range of motion of at least approximately 120 degrees. In some embodiments, third hinge may have a range of motion of at least approximately 130 degrees. This wider range of motion may enable planar body  102  to flex in such a way as to clear the walls of the cavity during insertion. The third hinge is preferably strong and capable of repeated flexing without damage. In an embodiment, the third hinge is a living hinge. Second side plate  140  may also include friction-enhancing feature  142  which may assist in retaining the bridge adapter in the cavity by engaging with the walls of the cavity. In an embodiment, as illustrated in  FIGS. 1A-1C , friction-enhancing feature  142  may include two raised bumps that may engage with the rough inner surface of the cavity. 
     Additionally, as illustrated in  FIGS. 1A-1C , bridge adapter  100  may also include tail  106  that is disposed along the second side plate back edge. Tail  106  may include a handle  108  located at the opposite end of the tail from the second side plate back edge. The handle may be curved to enable easier grasping and may include textured features to improve friction between the hand and the handle. Tail  106  is attached to the second side plate back edge by a removable connection; the removable connection is preferably a living hinge that is perforated to enable easy detachment without displacing the bridge adapter from its position in the cavity. The tail also includes a locking feature  107  that engages with the locking indent  119  when the bridge adapter is folded, locking it into a rectangular tube shape. The tail is preferably thinner than the body and is preferably stiff enough to be used to push the body into the cavity. The length of the tail is preferably sufficient to reach the bottom of the cavity without having the handle enter the cavity. 
     In an embodiment, one or more of the plates may include one or more support ribs  162  disposed along inner surfaces of the one or more plates. Support ribs  162  may be separately located along each plate as illustrated and may strengthen the plates in order for the bridge adapter to avoid flexing during use. In an embodiment, support ribs may extend from the front edge to the back edge of each plate and may have at least one thickness of the plate in width and thickness. Each plate may include any number of ribs. 
     As illustrated in  FIGS. 2A-2D , an embodiment of the bridge adapter may fold or bend into a rectangular tube shape. In  FIG. 2A , the bridge adapter is fully unfolded and top plate  110 , first side plate  120 , bottom plate  130 , and second side plate  140  are substantially coplanar. Tail  106  is also substantially coplanar with the four plates. The fully unfolded configuration of the bridge adapter may be used for storage or transport.  FIG. 2B  shows top plate  110  folded at an approximately 90 degree angle to first side plate  120 . First hinge  152  is folded to produce this folded configuration.  FIG. 2C  shows first side plate  120  folded at an approximately 90 degree angle to bottom plate  130 , with second hinge  154  being folded. Finally,  FIG. 2D  shows third hinge  156  folded as bottom plate  130  is folded at an approximately 90 degree angle to second side plate  140 . After all the hinges are folded and the plates form roughly 90 degree angles with respect to each other, top plate  110  is locked into the second side plate  140  and the bridge adapter assumes a rectangular tube shape. The locking may happen by the locking indent  119  snapping into the locking feature  107 . After the bridge adapter is locked into a rectangular tube shape, tail  106  may be detached. 
     Since the bridge adapter is a rectangular tube shape when folded, it will be understood that the first side plate and the second side plate are preferably the same width and that the top plate and bottom plate are preferably the same width (not necessarily the same as that of the first and second side plates). Different sizes of the bridge adapter may be available for differently sized locks and differently sized cavities. While the bridge adapter may be made of any material as long as it is sufficiently rigid to bear the weight of the bridge and the lock, in an embodiment, the bridge adapter is made of a polymeric material such as ABS, HDPE, or a similar rigid polymeric material. The first hinge, second hinge, and third hinge are preferably living hinges. 
     As illustrated in  FIGS. 3A-3C , bridge adapter embodiments may be inserted though an opening into cavity  300  within a door stile. Tail  306  may be used to insert the bridge adapter through an opening into cavity  300 , as shown in  FIG. 3A . After body  302  is partially inserted into cavity  300 , as shown in  FIG. 3B , the second and third hinge of the bridge adapter may be bended in such a way that the first side plate comes in contact with a wall of the cavity; the bottom plate comes in contact with the bottom of the cavity; and the second side plate comes in contact with another wall of the cavity as shown. In embodiments, the first hinge and the second hinge have a range of motion of more than approximately 90 degrees. In an embodiment, the third hinge has a range of motion of at least approximately 120 degrees to enable the bottom plate front edge and first side plate back edge to clear the wall of the cavity as the bridge adapter folds into position. In some embodiments, the third hinge has a range of motion at least approximately 130 degrees. 
     As illustrated in  FIG. 3C , the top plate of bridge adapter  302  is placed into position. In an embodiment, sufficient pressure may be applied to the top plate to engage the locking indent with the raised locking feature. In an embodiment, the tail may be detached after the bridge adapter is installed. The tail may be useful in positioning bridge adapter embodiments after the locking indent engages with the raised locking feature. The tail may be detached by any method known in the art such as by cutting or by tearing along a perforation. 
     It may be appreciated that in some examples, a cavity may be encountered that is deeper than one bridge adapter can accommodate. In such examples, a second bridge adapter may be needed. In an embodiment, a second bridge adapter may be installed on top of a first bridge adapter, as shown in  FIGS. 4A-4C . As illustrated in  FIG. 4A , a second bridge adapter may be inserted into cavity  400  into which a first bridge adapter is already installed. It may be noted that the tail of the first bridge adapter is not detached but passes along a cutout. In embodiments, both tails are detached only after both bridge adapters are installed. As noted above, tails may be useful in positioning bridge adapters after locking. In other embodiments, the tail of the first bridge adapter may be detached before the second bridge adapter is installed. 
     As shown in  FIG. 4B , the second bridge adapter may be installed in a manner similar to the first bridge adapter as shown in  FIG. 3B . Similarly to  FIG. 3B , the second and third hinge of the bridge adapter may be hinged in such a way that the first side plate comes in contact with a wall of the cavity; the bottom plate comes in contact with the bottom of the cavity; and the second side plate comes in contact with another wall of the cavity as shown. In embodiments, the first hinge and the second hinge have a range of motion of more than approximately 90 degrees. In an embodiment, the third hinge has a range of motion of at least approximately 120 degrees to enable the bottom plate front edge and first side plate back edge to clear the wall of the cavity as the bridge adapter folds into position. In some embodiments, the third hinge has a range of motion of at least approximately 130 degrees. Raised features  416 A and  416 B of the top plate of first bridge adapter  402  may engage the through holes (see  FIG. 1, 132A and 132B ) of the bottom plate of second bridge adapter  410 , locking the second bridge adapter into place. 
       FIG. 4C  illustrates the next stage of the installation of second bridge adapter  410 . As illustrated, after the bottom plate of the second bridge adapter is in contact with the top plate of the first bridge adapter and the first and second side plates of the second bridge adapter are in contact with the walls of the cavity, the first hinge is folded or bent to an approximately 90 degree angle by applying pressure to the top plate of the second bridge adapter. The pressure may be applied until the locking indent engages with the raised locking feature and the second bridge adapter is locked in place. In an embodiment, the tails of both bridge adapters may be detached after installation. The tail may be useful in positioning bridge adapter embodiments after the locking indent engages with the raised locking feature. The tail may be detached by any method known in the art such as by cutting or by tearing along a perforation. In an embodiment, one or both of the side plates includes a cutout of an approximate size and shape to accommodate the passage of a tail disposed along an outer surface of bridge adapter  400  (see  FIG. 1A, 126 ). This enables the second bridge adapter to be installed on top of a first bridge adapter without detaching the tail of the first bridge adapter. 
       FIGS. 5 and 6  installed bridge adapter embodiments and bridges in accordance with embodiments of the present invention. As utilized herein, a bridge is a structure which can support a mortise lock or faceplate.  FIG. 5  illustrates bridge adapter  510  installed in door stile  500 . Bridge  530  may be coupled with bridge adapter  510  as shown. In embodiments, a mortise lock or faceplate may then be coupled with and supported by bridge  530 . In some examples, a door stile may require an additional bridge adapter. Thus, as illustrated in  FIG. 6 , bridge adapter  610  may be installed in door stile  600 . Bridge  630  may be coupled with bridge adapter  610  as shown. In embodiments, a mortise lock or faceplate may then be coupled with and supported by bridge  630   
     As can be seen in  FIGS. 5 and 6 , the tails of the bridge adapters may be removed after installation. In an embodiment, the tail is connected with the body using a perforated living hinge that may be detached without special tools. In alternate embodiments, the tail may be made of a separate piece of material and attached to the body using adhesives or a fastener. 
     The terms “certain embodiments”, “an embodiment”, “embodiment”, “embodiments”, “the embodiment”, “the embodiments”, “one or more embodiments”, “some embodiments”, and “one embodiment” mean one or more (but not all) embodiments unless expressly specified otherwise. The terms “including”, “comprising”, “having” and variations thereof mean “including but not limited to”, unless expressly specified otherwise. The enumerated listing of items does not imply that any or all of the items are mutually exclusive, unless expressly specified otherwise. The terms “a”, “an” and “the” mean “one or more”, unless expressly specified otherwise. 
     While this invention has been described in terms of several embodiments, there are alterations, permutations, and equivalents, which fall within the scope of this invention. It should also be noted that there are many alternative ways of implementing the methods and apparatuses of the present invention. Furthermore, unless explicitly stated, any method embodiments described herein are not constrained to a particular order or sequence. Further, the Abstract is provided herein for convenience and should not be employed to construe or limit the overall invention, which is expressed in the claims. It is therefore intended that the following appended claims be interpreted as including all such alterations, permutations, and equivalents as fall within the true spirit and scope of the present invention.