Patent Publication Number: US-7707862-B2

Title: Multi-point door lock and offset extension bolt assembly

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application claims the benefit of, and is a continuation of, co-pending prior U.S. application Ser. No. 10/767,472, filed Jan. 29, 2004, which is expressly incorporated herein by reference and made a part hereof, and upon which a claim of priority is based. 

   FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
   Not applicable. 
   TECHNICAL FIELD 
   The present invention relates to a door lock and bolt assembly. More specifically, the present invention relates to a multi-point door lock extension bolt assembly with an adaptor enabling at least an extent of the extension bolt to be offset relative the lock mechanism and to be concealed within the door. 
   BACKGROUND OF THE INVENTION 
   Multi-point door lock systems used in connection with door assemblies are generally known in the art. Conventional multi-point lock systems are generally used in sliding door, swinging door and/or french door assemblies. Typical multi-point door lock systems include latch or bolt assemblies that extend from the lock unit to engage the door frame, thus enabling the door to be securely locked to the frame. Plural latches or bolts are used to provide added security by locking the door to the frame at a plurality of locations. For example, typical multi-point locking door assemblies include a central lock mechanism that controls a central latch, as well as at least one bolt mechanism that engages the door frame above or below the door. The bolt mechanism of such multi-point door locks has an elongated body that extends from the central lock mechanism to the door frame, typically in the form of an elongated extension bolt. For added security, most of such multi-point locking doors have extension bolts extending from the central lock to both the top frame, and the floor threshold or bottom frame member. The extension bolts of such devices are positioned along an edge of the door, or are located in a channel or other passageway within the door. 
   Examples of these types of prior art assemblies are shown in  FIGS. 1 and 2 .  FIG. 1  shows a door with a multi-point locking system that has an extension bolt extending from the central lock unit and exposed along an edge of the door member of the assembly. The edge faces outwardly towards the frame. This type of multi-point locking assembly, thereby has extension bolts passing along the outer edge of the door, usually along the edge that first separates from the door jamb during opening of the door. In the embodiment, the door edge may be slightly recessed to accommodate flush installation of the extension bolts.  FIG. 2  depicts an example of an alternative structure of a typical multi-point lock assembly.  FIG. 2  shows a multi-point lock assembly in which the extension bolts extend through an internal channel of the door, to engage the door frame at the top and/or bottom of the door. This type of door lock assembly, with an extension bolt passing through the body of the door, provides a locking bolt structure that is spaced inward of the door edge and is thereby concealed within the door. Depending on the specific application, this arrangement may provide added security by preventing tampering; and it provides a cleaner appearance with less exposed mechanical parts. 
   Each of these types of multi-point lock assemblies offer benefits that may make one preferred for use in a given situation. For example, there may be applications in which added security would be achieved by providing extension bolts that pass through the body of the door, rather than being exposed along an edge. Alternatively, it may be preferable to have the extension bolts located along the edge of the door, such as may be desired for ease of installation or replacement of an existing type of assembly and to mate with existing recesses in the door frame. It is understood that the central lock units of the lock assemblies of  FIGS. 1 and 2  have different structural configurations to accommodate the different structural configurations of the extension bolts. Each central lock unit is specific for its particular extension bolt configuration. Because of such needs, it would be beneficial to have available a lock assembly that may be adapted for use, capable of modification to accommodate either structure of an extension bolt. 
   Therefore, it is desirable to provide a multi-point locking assembly capable of such adaptation by a user, and that is suitable for alternate positioning the passage of extension bolts, or similar extension bolt members, relative the central locking mechanism. Further, it is desirable to provide an adaptable extension bolt assembly that is capable of being mounted to a central lock device configured for an extension bolt such as is shown in  FIG. 1 , and yet with an altered alignment to permit passage of the bolts inside the door such as is shown in  FIG. 2 . The present invention is provided to solve these as well as other needs. 
   SUMMARY OF THE INVENTION 
   The present invention provides a locking door assembly having a door member mounted to a door frame and moveable between at least an open and closed position, with a lock assembly having a central lock member positioned in the door member. The lock assembly has at least one actuator member connected to the central lock that is moveable along an axis of extension between a first position and second position. The assembly further has an extension bolt with an elongated body extending along a bolt axis, and a proximal end connected to the actuator member and a distal end with a projection configured to mate with a receiver for locking the door in position. The connection of the actuator and the extension bolt includes an adaptor body with an intermediate length extending transverse to the extension bolt axis. This arrangement defines an extent of separation of the extension bolt axis from the actuator axis. 
   The present invention also provides a multi-point lock assembly as described above, that is configured to be mounted in a door to provide a central lock assembly with an actuator moveable along an axis of movement, and an extension bolt with an elongated body axis. The actuator is secured to the extension bolt by an adaptor having a length that extends transverse the elongated bolt axis, thus placing the extension bolt axis a distance away from the actuator axis. The present invention further provides a lock assembly in which the connection of the extension bolt to the actuator is configured for alternate connection by a user. In a first configuration, the bolt and actuator are connected in linear relationship such that the axis of the extension bolt is in substantial alignment with the actuator axis. In a second configuration, the adaptor length is transverse to the bolt axis to separate the actuator axis a distance from the bolt axis. 
   The present invention further provides an adaptor for connecting an extension bolt to a central lock device of a multi-point lock assembly for a door. The adaptor has an adaptor body with a first end connected to a mating portion of the lock actuator member, and a second end connected to the elongated extension bolt. The adaptor has a body length, extending between the first end and the second end, which extends transverse to the elongated extension bolt. In this manner, the adaptor may be connected to the structure of a multi-point lock assembly to displace the extension bolt into alignment with an internal passageway through the associated door, spaced away from the edge of the door. 
   Other advantages and aspects of the present invention will become apparent upon reading the following description of the drawings and detailed description of the invention 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In accompanying drawings, in which like numerals are employed to designate like parts throughout the same, 
       FIG. 1  is a partial elevational view of a prior art door and multi-point lock assembly having an extension bolt assembly positioned along the edge of the door; 
       FIG. 2  is a partial elevational view of a prior art door and multi-point lock assembly having a concealed extension bolt assembly extending in a channel within the body of the door; 
       FIG. 3  is an elevational view of a door assembly and multi-point lock assembly in accordance with the present invention; 
       FIG. 4  is a partial perspective view of the multi-point door lock assembly of  FIG. 3 ; 
       FIG. 5  is a partial elevational view of the multi-point door lock assembly of  FIG. 3 ; 
       FIG. 6  is a partial sectional view of the assembly if  FIG. 5 , with the interior of the central lock assembly in view and connections of bolt components shown in broken lines; 
       FIG. 7  is a perspective view of the adaptor of the present invention; 
       FIG. 8  is a side view of the adaptor of the present invention; 
       FIG. 9  is a top view of the adaptor of the present invention; 
       FIG. 10  is a front elevation view of a face plate embodiment of a multi-point door lock assembly; 
       FIG. 11  is a side elevation view of the face plate embodiment of the multi-point door lock assembly of  FIG. 10 ; and 
       FIG. 12  is a rear elevation view of the face plate embodiment of the multi-point door lock assembly of  FIG. 10 . 
   

   DETAILED DESCRIPTION OF THE DRAWINGS 
   While this invention is susceptible of embodiments of many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention, with the understanding that the present disclosure is considered to be an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated. 
   Referring now to  FIG. 3 , there is shown a multi-point door locking assembly  10  of the present invention. The door lock assembly  10  is shown operatively connected to a conventional swinging door assembly  12 . The door assembly  12  comprises a primary door member  14  or movable member, mounted within a master door frame  18 . The primary door  14  is mounted by conventional means to provide reciprocal sliding and/or swinging movement within the door frame  18 , thereby enabling ingress and egress through the door assembly  12 . Such conventional mountings include hinge connections  20  along a jamb edge  22  of the door  14 , or cooperative sliding track arrangement (not shown) between the frame  18  and the door member  14 . In the embodiment shown, secondary door member  16  is also mounted to the door frame  18 , and is located adjacent the lock edge  24  of the door, opposite the door jamb edge  22 . The secondary door  16  also may be a movable door member capable of sliding and/or swinging within the door frame  18 , and having a locking assembly  10  as is depicted in the primary door member  14 , or some other locking structure. Alternatively, the door member is mounted without the use of a secondary door member  16 , such that a portion of the door frame is located adjacent the lock edge  24  of the door  14 . The multi-point door locking system  10  of this invention is operatively connected to the door assembly  12 , for enabling the door member  14  to be securely locked to the door frame  18 . In the present embodiment, the locking system  10  is connected to the primary door member  14 . It is also contemplated that the locking system  10  may be connected to the second door member  16 , if desired, without departing from the scope of the present invention. Therefore, use of the term door frame may be used in reference to any adjacent structure suitable for securement of the door, including a door frame jamb  18  or an adjacent door structure  16 . 
   The door frame  18  preferably has one or more lock bolt receivers  26  integral with the door frame  12  for receiving a bolt projection of the assembly for locking the door in a selected position. In the embodiment shown in  FIG. 3 , there is a top and bottom receiver  26 , each for receiving a respective bolt projection of the lock assembly  28 . The lock assembly  28  includes a central lock body  30  with at least one extension bolt assembly  32 . The extension bolt assembly  32  preferably includes an actuator member or actuator arm  34  and a connected extension bolt member  36 . 
   The body  30  of the central lock assembly  28  has an internal mechanism  38  configured for manipulation by a user to lock and unlock the door member  14  relative the door frame  18 . Manipulation of the central lock assembly, and resulting interface movement of the internal mechanism  38 , causes movement of the actuator arm  34  extending from the central lock body  30 . Such manipulation causes movement of the actuator  34  between a first position located close to the central lock body  30 , and a second position that is extended a distance further from the central lock body  30 . In the preferred embodiment, the actuator arm  34  moves between the first and second position along an axis of movement  40  ( FIG. 5 ). 
   As shown in  FIGS. 4-6 , the central lock body  30  includes a housing  42  providing a compartment for the internal mechanism  38 , and the actuator arm  34  preferably extends from the housing  42  at the lock edge  24  of the door  14 . In the preferred form of the invention, the multi-point lock arrangement includes a latch member  44  extending from the face plate  46  that extends along the lock edge  24  of the door  14 . The face plate  46  is preferably formed of flat sheet stock material such as metal, mounted directly to the outer surface  25  of the door edge  24 , and is thereby exposed along the lock edge  24  of the door  14 . 
   The lock assembly preferably includes a deadbolt member  48  that may be deployed to an extended position protruding from the face plate  46  to engage an associated portion of the door frame  18 , thereby providing one of the points of the multi-point locking arrangement. The lock assembly internal mechanism  38  is configured to be manipulated by a user to control locking engagement between the door member  14  and the door frame  18 , by controlling movement of the latch member  44 , the dead bolt member  48 , and each extension bolt assembly  32 . As shown in  FIG. 6 , the mechanism  38  of the central lock assembly  28  preferably includes at least one slide member  50  and an associated drive assembly  52 . The drive assembly  52  is operably connected to the slide member  50  to provide control of each actuator  34 , to move the actuator  34  between the first and second positions. This arrangement thereby provides operational connection of the drive assembly  52  to each extension bolt assembly  32 , through manipulation of each actuator arm  34 . Further details of components and operation of a suitable lock mechanism for use with this invention, such as that which is depicted in the Figures, is described in U.S. Pat. No. 6,209,931, entitled, “Multi-Point Door Locking System,” which has been assigned to the assignee of the present application, and incorporated herein by reference. Further details of components and operation of another suitable lock mechanism for use with this invention, such as that which is depicted in the Figures, is described in U.S. patent application Ser. No. 10/107,518, entitled “Multipoint Lock Assembly,” which has been assigned to the assignee of the present application, and incorporated herein by reference. 
   As further shown in  FIGS. 3-9 , the connection  58  of the actuator arm  34  to the extension bolt member  36  according to the present invention includes an adaptor  60  that provides structure for displacing the extension bolt axis  62 . More specifically, the adaptor  60  has a first end  64  connected to the actuator arm  34  and a second end  66  connected to the extension bolt member  36 . In the preferred form of the invention, the first end  64  of the adaptor  60  has a projection  68  dimensioned to be received in mating arrangement with a receiver  70  of the actuator arm  34 . The mating arrangement of the projection  68  into the receiver  70  provides connection of the adaptor  60  to the actuator  34  by a friction fit at the first end of the adaptor  60 . This connection may also include engagement or locking with a mechanical fastener, such as a retaining washer or threaded fastener arrangement (not shown), without departing from the structural benefits of the present invention. 
   The second end  66  of the adaptor  60  is configured for secure connection with the extension bolt member  36 . The connection of these components includes a mating arrangement of a second projection  72  and a second receiver  74 . In the embodiment shown in the figures, the second receiver  74  is formed as part of the adaptor  60 , and the mating second projection  72  is formed as part of the extension bolt member  36 . However, this arrangement may be reversed while still practicing the invention. In this manner, the second projection is optionally formed as part of the adaptor  60 , either with or without threading, and the second receiver may be formed as part of the extension member  36 . This mating arrangement between the adaptor  60  and the extension member  36 , either through friction fit or mechanical fastening, provides a connection that securely joins the adaptor  60  such that movement of the adaptor  60  by manipulation of the actuator arm  34  will transfer force of movement to the extension member  36 . In other words, movement of the actuator arm  34  from the first position to the second position (described above) causes the adaptor  60  to move away from the central lock body  30 , and thereby causes the extension member  36  to move along the axis  62  of the member  36 . Movement of the extension member  36  thereby results in deployment of the bolt projection  76  located at the distal end of the extension member, whereby the bolt projection is inserted into a receiver  26  of the door frame  18 . 
   One benefit of having a such an assembly with an adaptor  60  is that it provides structure to position the extension bolt  36  in the interior of the door member  14 , while maintaining use of the actuator arm  34  located along the lock edge  24  of the door  14 . This is achieved by altering the position of the movement axis  40  of the actuator arm  34  separate from the axis  62  of the extension bolt  36 . As is shown in the Figures, such displacement of the bolt axis  62  from the actuator axis  40  is provided by the adaptor  60  having a body  80  with a body length  82  extending between the first end  64  and the second end  66 . Because the body length  82  passes transverse the actuator axis  40  and the extension bolt axis  62 , the extent of the body length  82  defines the extent of displacement of the two axes  40 , 62 . In the preferred embodiment, the body length  82  is a fixed length between the mounting of the actuator  34  at the first end  64  and the mounting of the extension bolt  36  at the second end  66 . Accordingly, the body length  82  is preferably constant and defined by the extent of the adaptor body  80 ; and, therefore, does not include an extent of threading or similar such structure that would vary the extent of the length  82  such as by tightening a threaded arrangement. In an alternate embodiment (not shown), in which the length  82  may be adjusted to provide adjustable displacement of connection  58 , it is preferable for no portion of the length  82  being formed of threaded arrangement of connecting the adaptor  60  to either the actuator  34  or the extension bolt member  36 . It is understood that the body length  82  could have non-transverse configurations, such as diagonal configuration, that still provides displacement, or an offset of the two axes  40 , 62 . 
   In another embodiment of the invention, the assembly  10  includes a lock assembly  28  with structure that is adaptable between a first configuration ( FIG. 1 ) whereby the axis of the extension bolt is in substantial alignment with the actuator axis (such as with that of prior art assemblies as shown in  FIG. 1 ), and a second configuration ( FIG. 3 ) whereby the axis  62  of the extension bolt  36  resides a distance away from the actuator axis  40 . Such alternating configuration is provided by a structure that allows optional use of the adaptor  60  as part of the connection  58  between the actuator  34  and the extension bolt member  36 . If the user elects to have the extension bolt member  36  located along the lock edge  24  of the door  14 , then the user links the connection  58  of the actuator  34  to the extension bolt  36  without the use of an adaptor having a length transverse either axis  40 , 62 . Alternatively, if the user elects to configure the assembly  10  for an extent of extension bolt(s)  36  to pass through an interior portion of the door  14 , spaced from the lock edge  24 , then the connection  58  includes the adaptor  60  with the transverse length  82 . With such possible configurations, a single central lock unit, such as shown in  FIG. 1  or  3 - 6 , can be used in an extension bolt configuration positioned at an edge of the door, or a concealed extension bolt configuration. 
   As shown in the Figures, the preferred embodiment of the invention includes an assembly with at least two extension bolt assemblies  32 , one above and one below the central lock  28  assembly. The top extension member  36   a  extends through the door  14  to engage a top receiver of the door frame  18 , and the lower extension member  36   b  extends through the door  14  to engage with a receiver in the frame  18  below the door  14 . Extension bolt members  36  may be provided in a variety of lengths to accommodate different doors or applications, and may be engaged for locking by structure differing from the traditional bolt projection structure, such as by use of hooks or other locking elements or mechanisms for securement to the frame  18 . 
   In another configuration, the extension bolts may be installed to extend along a lock edge  24  of a door  14 , as depicted in  FIGS. 10-12 , and similar to the embodiment illustrated in  FIG. 1 . In this configuration, the actuators  34  are connected to an extension bolt  218 ,  220 , each extending along a bolt axis, and the axis of each actuator  34  is in alignment with the bolt axis of each bolt  218 ,  220 . As depicted in  FIGS. 10-12 , an actuator  34  extends through a top slot in housing  228 . Similarly, an actuator  34  extends through a bottom slot in housing  228 . Each actuator  34  is coupled to slide plate which is actuated by the internal mechanism of the central lock body  30 . As the internal mechanism is turned in the counterclockwise direction, actuators are extended from housing  228 , similarly to the other embodiments described herein. As depicted in  FIGS. 11-12 , actuators  34  are coupled to extension bolts  218  and  220  respectively by pins  222  and  224  respectively. A series of spacer guides  226  have columnar pins  227 , running therethrough; the spacer guides  226  ride in elongated slots  228 . Columnar pins  222  may be provided by, for example, appropriate fasteners such as but not limited to bolts, rivets, nails, or screws. Extension bolts  218  and  220  each have extension bolt tips  230  and  232  respectively. Extension bolt tips  230  and  232  extend into the door frame to securely latch door  14  to a door frame, such as the door and door frame as depicted in  FIG. 1 .  FIG. 10  depicts face plate system  200  having a face plate  202 . Face plate  202  runs along the lock edge  24  of door  14 . 
   To install face plate system  200  on a door such as door  14 , an operator would form a mortise hole in door  14  having a size and shape that would accommodate insertion of the lock unit  30  therein. Also, an operator would provide a routed groove along edge  24  of door  14  that would accommodate the face plate system  200  such that face plate  202  would reside substantially flush with edge  24  of door  14 . When face plate assembly  200  is properly positioned, a plurality of pins  227  (or suitable fasteners) may be used to affix assembly  200  to edge  24  of door  14 . Pins  227  would extend into edge  24  of door  14  to fasten assembly  200  thereto. It should be noted that extension bolts  218  and  220  may be provided in a variety of lengths to accommodate different door sizes. Further, it should also be noted that a variety of extension bolt tips  230  and  232  may be used with extension bolts  218  and  220  to provide customized output suitable for the application. 
   In operation, the multi-point locking system  10  controls locking engagement between the door member  14  and the door frame  18 . Movement of the internal mechanism  38  causes the slide member  50  to move, and thereby move the actuator arm  34  along its axis  40 . Such movement of the actuator  34  forces movement of the extension bolt  36 , to force the bolt in and out of engagement with the receiver  26  in the door frame  18 . The adaptor  60 , being the connection of the actuator  34  to the extension bolt  36 , preferably moves with the actuator and the bolt  36 , providing solid connection between the bolt and actuator. Alternatively, the adaptor may affect such movement as a fixed component with respective moving parts connected to the actuator and the bolt, without departing from the present invention. 
   While the specific embodiments have been illustrated and described, slight modifications of the specific embodiments shown herein are readily available, without significantly departing from the spirit of the present invention and the scope of protection provided by the Claims.