Patent Publication Number: US-6988751-B2

Title: Non-rotational lock chassis assembly

Description:
FIELD OF THE INVENTION 
   The present invention relates to a lock assembly. In particular, this invention relates to a non-rotational lock chassis assembly for a door. 
   BACKGROUND OF INVENTION 
   Certain door lock assemblies generally include a latch assembly supported by a lock chassis. The latch assembly extends and retracts a latch in securing access through the door. The lock chassis supports the operation of the latch assembly inside the door. 
   SUMMARY OF THE INVENTION 
   A problem in the industry with lock assemblies is their susceptibility to rotation inside the door, interrupting the operation of the latch assembly. The non-rotational lock chassis assembly of the invention constrains rotation of the chassis as well as allows adjustment for centering the chassis in doors having varying thicknesses. 
   One embodiment of the invention is a non-rotational lock chassis assembly for a door that includes a chassis having a first hub and a second hub, a first plate having a first opening with at least one flat side for receiving the first hub of the lock chassis, a second plate having a second opening with a threaded interior for receiving the second hub of the chassis, at least one connecting element that interconnects the first plate and the second plate, wherein the first plate and the second plate engage the at least one connecting element to constrain rotation of the chassis inside the door. 
   A second embodiment of the invention is a lock assembly for a door that includes a latch assembly having a latch that extends and retracts to secure the door, a chassis in support of the latch assembly, the chassis having an integral first hub and second hub, a first spring cage having a first spindle that rotates to extend and retract the latch assembly, a second spring cage having a second spindle that rotates to extend and retract the latch, a first plate having a first opening with at least one flat side that receives the first hub, the first plate positioned between the first spring cage and first hub, a second plate having a second opening with a threaded interior that receives the second hub, the second plate positioned between the second spring cage and second hub, at least one connecting element that interconnects the first and second spring cages, and wherein the at least one connecting element engages the first and second plates to constrain rotation of the chassis. 
   As is apparent from the above, it is an aspect of the invention to provide a non-rotational chassis assembly for a lock assembly of a door. 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 perspective view of an exemplary lock assembly embodying the invention. 
       FIG. 2  is a perspective view of a chassis and latch assembly embodying the invention. 
       FIG. 3  is a perspective view of a non-rotating plate embodying the invention. 
       FIG. 4  is a perspective view of a threaded plate embodying the invention. 
       FIG. 5  is a perspective view of an inside spring cage. 
       FIG. 6  is a perspective view underneath an inside spring cage. 
   

   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 an exemplary embodiment of the lock assembly  5  of the invention. The lock assembly  5  includes a non-rotational chassis assembly  10  in support of a latch assembly  15 . The non-rotational chassis assembly  10  of the invention includes a chassis  20  having a first  25  and a second hub  30 , a non-rotational plate  40  that receives the first hub  25  and a threaded plate  45  that receives the second hub  30 . At least one connecting element  47  interconnects the non-rotational plate  40  and the threaded plate  45  in constraining the chassis  20  from rotating inside the door. Spring cages  50  and  55  include drive spindles  60  and  65 , respectively, that rotate to linearly extend and retract the latch assembly  15  between a locked and an unlocked position, respectively. 
     FIG. 2  shows a perspective view of an exemplary latch assembly  15  supported by the chassis  20 . The latch assembly  15  includes a retractor assembly  70  that extends and retracts a beveled latch or bolt  75  from a locked position to an unlocked position, respectively. Drive shafts  80  and  85  extend from each side of the retractor assembly  70  and pass through openings in the lock chassis assembly  10 . Each drive shaft  80  and  85  rotates to move the retractor assembly  70  in a linear direction, thereby retracting and extending the beveled latch  75  to secure access through a door. 
   The chassis  20  includes the first  25  hub and the second hub  30 . The drive shafts  80  and  85  extend through the first  25  and second  30  hubs, respectively, to engage the drive spindles  60  and  65  of the spring cages  50  and  55 , respectively. One embodiment of the first hub  25  includes at least one flat side  110 . As shown in  FIGS. 1 and 2 , the exemplary first hub  25  is substantially octagonal-shaped. Of course, the first hub  25  can include other suitable shapes (e.g., square, elliptical, etc.). Another embodiment of the first hub  25  includes a key  112  for aligning the non-rotational plate  40  with the hub  25 . 
   One embodiment of the second hub  30  includes a threaded exterior  116  for receiving the threaded plate  45 . In yet another embodiment of the invention, the second hub  30  can include at least one flat side as described above, and the first hub  25  can include the threaded exterior  116 . In an alternative embodiment of the invention, both the first  25  and second  30  hubs can include at least one flat side as described above for the first hub  25 . However, not providing at least one threaded plate and hub reduces the ability to adjust lock assembly  5  for the thickness of the door. 
   The exemplary first hub  25  is mounted to the chassis  20  using mounting screws  114 . As shown in  FIG. 2 , two mounting screws  114   a  and  114   b  secure the hub  25  to the chassis  20 . Of course, other suitable connection means (e.g., spot-weld, cast, etc.) known to those in the art can be used. The exemplary embodiment of the first  25  and second  30  hubs of the chassis  20  is comprised of a zinc composition. Of course, the hubs  25  and  30  can be comprised of other suitable materials and compositions (e.g., iron, steel, plastic, etc.) known to those in the art. 
     FIG. 3  shows a perspective view of an exemplary non-rotational plate  40  of the invention. The non-rotational plate  40  includes an extension or boss  140  having an opening  145  for receiving the first hub  25  of the chassis. The extension  140  is of length such that the plate  40  lies substantially flush with the top surface of the hub  25 . The opening  145  is shaped for receiving the hub  25  of the chassis  20 . In one embodiment, the opening  145  includes at least one flat side  147  for engaging the at least one flat side  110  of the chassis  20 . In  FIG. 3 , the exemplary embodiment of the non-rotational plate  40  a flat sides  147   a  and  147   b  that are compatible for receiving the exemplary hub  25  of the chassis  20  described above. Of course, the opening  145  can take other shapes compatible to receive the hub  25 . The non-rotational plate  40  further includes at least one cutout or slot  150  located along the plate&#39;s perimeter.  FIG. 3  shows an exemplary non-rotational plate  40  having a first  150   a  and second slot  150   b . The at least one slot  150  engages connector elements  47  extending from the non-rotational plate  40  to the threaded plate  45 . The engagement of the slots  150   a  and  150   b  with the connecting elements  47  constrains the chassis  20  from rotating in the door. In another embodiment, the plate  40  can include at least one hole in a position to receive the connector element  47  described above. In another embodiment, the non-rotational plate  40  includes an alignment notch or extension  155  that engages the key  112  in the hub  25 . 
     FIG. 4  shows an exemplary threaded plate  45  of the invention. The threaded plate  45  includes an extension or boss  160  having a threaded interior  165 . The threaded interior  165  is designed to accept or receive the threaded exterior  116  of the second hub  30  of the chassis  20  described above. The depth of the boss  160  is designed to match the depth of the threaded hub  30 . One embodiment of the threaded plate  45  further includes at least one notch or slot  170  located along the plate&#39;s perimeter similar to the non-rotational plate  40  described above.  FIG. 5  shows the threaded plate  45  having a first  170   a  and second  170   b  slot. The slot  170  is designed to receive and engage the connecting element  47  in constraining the chassis  20  from rotating with actuation of the latch assembly  15 . The slots  170  are positioned along the threaded plate  45  to align with the slots  150  of the non-rotational plate  40 . The slots  150   a  and  150   b  of the non-rotational plate  40  and slots  170   a  and  170   b  of the threaded plate  45  engage the connector elements  47  in substantially the same manner. Of course, holes or extensions at the non-rotational plate  40  or threaded plate  45  can be used to engage the connecting elements  47 . 
   As noted above the non-rotational plate  40  and threaded plate  65  are interchangeable to match the exterior of the first  25  and second  30  hubs of the chassis  20 . One embodiment of the non-rotational plate  40  and threaded plate  65  are comprised of steel. Alternatively, the non-rotational plate  40  and threaded plate  65  can be comprised of other suitable materials (e.g., forged metal, plastic) known to those in the art. 
   As described above, the connecting elements  47  engage the non-rotational plate  40  and threaded plate  45  in constraining rotation of the chassis  20 . In one embodiment, the connecting elements  47  are threaded bolts. Of course, other suitable connecting elements (e.g., rods, etc.) known to those in the art can be used. 
   As shown in  FIGS. 5 and 6 , the connecting elements  47  can include interior threaded posts  175  attached at the spring cages  50  and  55 . The exemplary posts  175  include a threaded interior for receiving a connecting element  47  having a threaded exterior. The posts  175  can attach at either one or both ends of the connecting elements  47 . In another embodiment, slots  150  or  170  of the plates  40  and  45  engage the posts  175  interconnected by the connecting elements  47 . Of course, the post  175  can vary in length and be located at one or both spring cages  50  and  55 . Any suitable means of connecting the posts  175  to the inside spring cages  50  and  55  can be used. Additionally, other suitable connecting elements  47  (e.g., bolts, nuts, etc.) can be used. 
     FIGS. 5 and 6  illustrate one embodiment of spring cage  50 . Many of the elements of the embodiment of spring cage  50  illustrated in  FIGS. 5 and 6  are the same or similar to those used in the embodiment of the spring cage  55  illustrated in FIG.  1  and operate in the same or similar manner. Accordingly, the description of the various elements of spring cage  50  illustrated in  FIGS. 5 and 6  can be found in spring cage  55 . 
   As shown in  FIGS. 5 and 6 , the spring cage  50  includes the drive spindle  60  extending through a housing or cover  180 . One end of the drive spindle  60  connects to a door lever (not shown). The drive shaft  80 ,  85  passes through an opening  182  surrounded by a boss  184  in the cover  180 . A retainer ring  190  is positioned around the spindle  60  at the opening  182  to secure the drive spindle  60  to the cover  180 . 
   The other end of the drive spindle  60  is integral with a torque plate  185  that biases underneath the cover  180 . One embodiment of the torque plate  185  includes a hallowed radial area for positioning at least one spring or spring component  190  (shown hidden by dashed lines). The hollowed area of the torque plate  185  creates a raceway with the boss  184  of the cover  180  for the positioning the at least one spring or spring components  190 . Tabs located radially along the boss  184  of the cover  180  and tabs located radially on the torque plate  185  compress the springs  190 . The springs  190  bias rotation of the drive spindle  60  back to its original position. 
   As shown in  FIGS. 5 and 6 , the exemplary embodiment of the torque plate  185  further includes at least one drive slot  210  that engages extensions  200  at the drive shafts  80  and  85 . Engagement of the drive slot  210  and torque plate  185  with the extensions  200  on the drive shaft  80  enables rotation by a door lever to extend and retract the latch assembly  15 . 
   The exemplary embodiment of the cover  180  further includes at least one connector opening or slot  215  for receiving the at least one connecting element  47 . In one embodiment, the connecting elements  47  extend through the openings  215  to interconnect the spring cages  50  and  55  with the non-rotational plate  40 , threaded plate  45 , and chassis  20 . The non-rotational plate  40  and threaded plate  65  further include a pair of flat portions  222  located along the perimeter. The flat portions  222  provide a space to accommodate the rose indents  220 . 
   As shown in  FIGS. 5 and 6 , another embodiment of the cover  180  includes a plurality of plate supports  225  positioned in the interior along the rim of the cover  180 . The plate supports  225  support the non-rotational plate  40  and threaded plate  45  positioned underneath the cover  180 . 
   Thus, the invention provides, among other things, a non-rotational lock chassis assembly. Various features and advantages of the invention are set forth in the following claims.