Patent Publication Number: US-11035148-B2

Title: Return cartridge for door handles

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation of U.S. patent application Ser. No. 14/879,379, filed Oct. 9, 2015, the entire contents of which are hereby incorporated by reference. 
    
    
     FIELD OF DISCLOSURE 
     The present disclosure relates to the operation of door handles and corresponding locking and latching components. More particularly, the present disclosure relates to door components that bias the position and rotation of door handles. 
     BACKGROUND 
     Door handles are present on nearly every door in a home. Typically these handles rotate to retract a latch and allow the door to be swung open. Then, in almost every case, the handle automatically returns to its original home position with the latch extending from the door stile once again. Handle return components can be prone to wear after repeated use over time. As these components wear, the force available to return the handle to the home position weakens. In some cases, where the handle is a lever, the weight of the lever causes a torque around the axis of rotation and may eventually lead to the handle sagging, i.e. resting below an intended home position. 
     Some handles are biased to a home position by features incorporated into the case of a mortise lock. These embodiments may require replacement of an entire lock if the lever return mechanism becomes worn. In other existing embodiments, biasing features are integrated with escutcheons on either side of the door. Escutcheons, however, are often uniquely configured for placement on either an interior or exterior side of door. As a result, the handing of the door must be known in order to acquire the proper set of escutcheons with integrated biasing features. 
     There is a need for a handle return design that allows for improvements associated with the installation or replacement of these elements eliminating the need for prior knowledge of a door&#39;s handing. 
     SUMMARY 
     The present disclosure describes a handle return assembly removably attachable to an escutcheon. The removable assembly may include a housing to be attached to the escutcheon and a hub rotatably disposed within the housing for operably connecting an operating handle to a drive spindle. A spring may bias the hub toward an initial, home position. At least one stopper plate may interact with the housing for limiting rotational motion of the hub relative to the housing. 
     Other embodiments include a handle return assembly separate from but removably attachable to an escutcheon. The handle return assembly is configured to interact with a handle such that the handle is biased to an initial home position and the handle is rotatable relative to the escutcheon about a predetermined sweep angle in a single direction relative to the home position to define a left-handed or right-handed operation. The assembly can be disassembled and reassembled using the same parts to change the operation of the assembly among left-handed, right-handed and a non-operating configuration where rotation in neither direction is permitted. 
     Other embodiments include a door hardware kit having an exterior escutcheon, an interior escutcheon, a first handle return cartridge configured to provide left-handed operation, and a second handle return cartridge configured to provide right-handed operation. Each handle return cartridge may be capable of being attached to either escutcheon such that the elements of the kit may be selectively assembled to operate a left-hand or a right-hand door. 
     These and other features of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiments, when considered in conjunction with the drawings. It should be understood that both the foregoing general description and the following detailed description are explanatory only and are not restrictive of the invention as claimed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a door having a kit according to embodiments of the present disclosure install thereon. 
         FIG. 2  is an exploded view of the installed kit from  FIG. 1 . 
         FIG. 3  is a handle-side view of a handle return module. 
         FIG. 4  is a lock-side perspective view of a handle return module assembled for right-handed operation. 
         FIG. 5  is an exploded view of the handle return assembly of  FIG. 4 . 
         FIG. 6  is a perspective view of a hub according to embodiments of the handle return assembly. 
         FIG. 7  is a lock-side view of a handle return module assembled for left-handed operation. 
         FIG. 8  is a lock-side perspective view of a handle return module assembled for a non-operating application. 
         FIG. 9  is a lock-side view of another handle return module. 
         FIG. 10  is a handle-side perspective view of a housing according to another embodiment. 
         FIG. 11  is a lock-side perspective view of the housing in  FIG. 10 . 
     
    
    
     The foregoing and still other objects and advantages of the present invention will be more apparent from the following detailed explanation of embodiments of the invention in connection with the accompanying drawings. 
     DETAILED DESCRIPTION 
     Exemplary embodiments of this disclosure are described below and illustrated in the accompanying figures, in which like numerals refer to like parts throughout the several views. The embodiments described provide examples and should not be interpreted as limiting the scope of the invention. Other embodiments, and modifications and improvements of the described embodiments, will occur to those skilled in the art and all such other embodiments, modifications and improvements are within the scope of the present invention. Features from one embodiment or aspect may be combined with features from any other embodiment or aspect in any appropriate combination. For example, any individual or collective features of method aspects or embodiments may be applied to apparatus, product or component aspects or embodiments and vice versa. 
     In practice today, handles can be biased to a home position by features incorporated into the case of a mortise lock. As used herein, the terms initial position and home position may be used interchangeably to describe the position of components under the biasing force of return features without added external forces, e.g. forces applied by a user. When these biasing features wear out, the entire lock mechanism must be replaced. In other existing embodiments, biasing features are integrated with escutcheons on either side of the door. Escutcheons, however, are often uniquely configured for placement on either an interior or exterior side of the door. As a result, the handing of the door must be known in order to acquire the proper set of escutcheons with integrated biasing features. As is known in the art, door handing may be determined based on facing the exterior of the door, determining whether the hinge for the door is on the right or the left, and determining whether the door will swing open toward the interior or the exterior. The handing of the door may affect the hardware so that the desired rotation of the handles results in the proper motion of the lock. 
     Embodiments of the present disclosure improve upon these existing designs by having handle return modules, also referred to as handle return assemblies or handle return cartridges, that may be removably attached to the preferred escutcheon. As a result, the handle return modules may be independently replaced if they become worn. Further, installation of a door hardware kit having the described handle return modules will not require predetermined knowledge of the handing of the door, potentially providing a benefit to the installer, and potentially providing a benefit, by way of inventory control, for the manufacturer. 
       FIG. 1  is an interior perspective view of a door  10  having right-hand operation in a slightly open position. As is known in the art, right-hand operation occurs when, facing an exterior of the door, the hinge is on the right and the door swings inward. Inswing entryway doors are commonly found in residential settings. The door  10  is generally provided with a lock  12 , such as a mortise lock, and door hardware  14  provided on the door  10  to interact with and operate the lock  12 . 
     The door  10  may be described in terms of an interior side  16  and an opposite exterior side  18 . A stile  20  extends along the edge of the door  10  between the interior side  16  and the exterior side  18 . The stile  20  may be provided with a cavity or mortise to accommodate one or more portions of the lock  12 . The type of lock  12  is not particularly limited for the purposes of this disclosure. Features and advantages of this disclosure, however, may be particularly applicable to multi-point mortise locks that have several spaced apart latches  22  extending and retracting relative to a stile  20 , all driven in response to input through the door hardware  14 . 
       FIG. 2  is an exploded view of the door  10  from  FIG. 1 . Elements of the door hardware will now be described in more detail. Some or all of the components of the door hardware may be provided in the form of a kit of unassembled or partially assembled parts that may be assembled upon the door  10  to operate the lock  12  as well as potentially provide other security and sealing functions. 
     The door hardware  14  ( FIG. 1 ) may include an interior escutcheon  24 , and an exterior escutcheon  26 . In some embodiments the interior and exterior escutcheons  24 ,  26  may be substantially similar. In other embodiments, the interior and exterior escutcheons  24 ,  26  may have one or more unique features. In one example, the interior escutcheon  24  may have mounting apertures  28  that are not visible on the exterior escutcheon  26 . In other example, the shape of a collar  30  may be different on each of the escutcheons  24 ,  26 . In the illustrated embodiment, the escutcheons  24 ,  26  each have a latch region  32  and a deadbolt region  34 . The deadbolt region  34  is optional. 
     Where present, the deadbolt region  34  may correspond with additional optional components for the operation of a deadbolt feature within the lock  12 . For example,  FIG. 2  shows the interior escutcheon  24  assembled with a thumbturn  36 . When fully assembled the thumbturn  36  may operate a key cylinder  38  shown installed on the exterior escutcheon  26 . The key cylinder  38  may be provided separate from or preassembled with the exterior escutcheon  26 . The key cylinder  38  may be provided along with one or more keys (not shown), one or more drive rods  40 , and any fasteners necessary to combine the key cylinder  38  to the exterior escutcheon  26 . 
     Continuing with  FIG. 2 , the kit of door hardware may also include a set of two door handles  42 , one for the interior side  16  of the door  10  and one for the exterior side  18  of the door  10 . The configuration of each handle  42  is not particularly limited. To provide a mechanical advantage when operating a multi-point lock, however, lever style handles as shown may be used. 
     The door hardware also includes at least one handle return module  44 . The handle return module may also be referred to interchangeably as a handle return assembly, unit or cartridge. Each handle return module  44  is configured to separate from the escutcheons, for example being removably coupled to an escutcheon by one or more fasteners  46 . In most embodiments, the door hardware  14  ( FIG. 1 ) includes a right-handed handle return module  44 R and a left-handed handle return module  44 L. In the illustrated embodiment, door  10  is right-handed. Therefore the right-handed handle return module  44 R corresponds with the exterior escutcheon  26  and the left-handed handle return module  44 L corresponds with the interior escutcheon  24 . When assembled with their respective handles  42 , each handle return module is configured to provide a biasing force that is designed to return each handle  42  to an initial, home position. In the case of lever type handles, the home position is generally understood as a horizontal position of the lever, where the handle is operated by rotating the handle downward. 
     The door hardware  14  ( FIG. 1 ) may include other features and elements provided to facilitate assembly and use of the components discussed above. One or more spindles  48  may be used to transfer motion from the handles  42  or the handle return modules  44  to the lock  12 . Additional elements may include one or more escutcheon gaskets  50  for sealing an escutcheon  24 ,  26  to a respective side of the door  10 . The door hardware may also include mounting screws  52  to attach the escutcheons  24 ,  26  to the door  10  and other fasteners for assembling the handles  42  onto respective handle return modules  44 . A kit having all or some of the door hardware may also include written instructions for the assembly of the door hardware as well as some or all of the tools necessary, e.g. an Allen wrench, for the assembly of the door hardware. 
       FIG. 3  shows a handle-side perspective view of the right-handed handle return module  44 R in a home position. The home position is the position of the components under the bias force provided by the handle return module  44 . As used herein, the handle-side is the side of the handle return module  44  that faces toward a respective handle  42 . Opposite the handle-side is the lock-side, the portion of the handle return module  44  that faces toward the lock  12 . With this convention, the sides of the handle return modules  44  are fixed without regard to the interior and exterior of the building or whether a handle return module  44  is associated with the interior escutcheon  24  or the exterior escutcheon  26 . 
     Each handle return module  44  may include a housing  54  and a hub  56 . The hub  56  may be disposed at least partially within the housing  54 . The hub  56  may be generally cylindrical in shape and configured to rotate with respect to the housing  54  about a central rotation axis A. The handle-side of the hub  56  may include a handle-side recess  58  for accepting a portion of a corresponding handle  42 . The handle-side recess  58  may be square or polygonal in shape to assist with transferring rotation of a handle  42  around rotation axis A to rotation of the hub  56  within the housing  54 . The hub  56  may also include a flange  60  with a keyed portion  62 . The keyed portion  62  may be arranged to correspond with an indicia  64  on the housing  54  when the handle return module  44  is in the home position to indicate whether the handle return module  44  has been assembled for right-handed or left-handed operation. Where the indicia  64  is used, a similar marker may be located on the housing  54  at a position rotated 180 degrees around the rotation axis A. When the indicia  64  is provided, the hub  56  may be shifted 180 degrees relative to the rotation axis A into a home position for a left-handed return module. In other embodiments, indication of handing may be provided by other features, such as a label applied during assembly. Where the permanent indicia  64  is not provided, the hub  56  may be similarly positioned relative to the housing  54  in both a right-handed and left-handed assembly. 
     The housing  54  may include one or more wings  66  projecting in a radial direction from the housing  54  with respect to the rotation axis A. The wings  66  may be provided for locating mounting apertures  68  for use when attaching the handle return module  44  to the appropriate escutcheon  24 ,  26 . 
       FIG. 4  is a lock-side perspective view of a right-handed handle return module  44 R in the home position. From the illustrated view, the hub  56  may be forced to rotate counter-clockwise about rotation axis A relative to the housing  54  and would be biased to rotate back to the home position after an outside force were removed. The wings  66  of the housing  54  may provide abutment surfaces  70 . The housing  54  may also be provided with additional protrusions  72  that also provide abutment surfaces  70 . A first set of abutment surfaces  70 A may act to limit rotation at the home position, and a second set of abutment surfaces  70 B may act to limit rotation is a direction away from the home position. As will become apparent, depending upon the handing of the handle return module  44 , the first and second set of abutment surfaces  70 A,  70 B may provide stops at the home position and the extended position respectively for one handing and vice versa for the other handing. 
     The handle return module  44  includes at least one stopper plate  74 . In  FIG. 4 , two stopper plates  74  are shown. The stopper plates  74  are configured to rotate with the hub  56  relative to the housing  54 . The stopper plates  74  have a peripheral shape to stop rotation of the hub  56  by contact with the abutment surfaces  70  at both the home and extended positions. 
       FIG. 5  is an exploded view of the right-handed handle return module  44 R. The handle return module includes the housing  54  and the hub  56 . A bushing  76  may be provided around the hub  56  and between the hub  56  and an interior of the housing  54  for reducing friction as the hub  56  is configured to rotate within the housing  54 . A push washer  78  may be provided around a portion of the hub  56  to help maintain proper alignment of elements along the rotation axis A. A spring  80 , such as a torsion spring, may be used to create the return or biasing force for which the handle return module  44  is used. A spiral-type torsion spring is shown in the illustrated embodiment and provides a compact package for use in the handle return module  44 . The spring  80  has a radially outer leg  82  and a radially inner leg  84 . The radially outer leg  82  may engage a notch  86  in the housing  54 . The radially inner leg  84  may engage a slot  88  in the outer surface of the hub  56  as seen in  FIG. 6 . In some embodiments, a single slot  88  may be provided. In other embodiments, a slot  88  may be provided at two symmetrically opposed locations. From the perspective of  FIGS. 4 and 5 , as the hub  56  rotates counter-clockwise within the housing  54 , the spring  80  stores energy that biases the hub  56  to rotate back in the clock-wise direction after an outside force, e.g. an operator rotating a handle  42 , is removed. 
     As mentioned above, one or more stopper plates  74  are provided to rotate along with the hub  56  and limit rotational motion, such as direction and angular magnitude, relative to the housing  54 . Referring to  FIG. 5 , in one embodiment, the stopper plates  74  have a generally annular shape with a portion of the hub  56  capable of passing through a central opening in each stopper plate  74 . The stopper plates  74  may have one or more ribs  90  extending into the central opening and configured to align with an engage one or more channels  92  provided along the hub  56 . The rib and channel design shown is only one embodiment. Any mating features provided on the hub  56  and the stopper plates  74  that allow for the stopper plates  74  to rotate with the hub  56  may be sufficient in view of other features discussed below. Suitable mating features may simply include flat portions of the otherwise circular central opening of the stopper plates  74  and corresponding outer periphery of the hub  56 . 
     Referring back to  FIG. 4 , the stopper plates  74  are also configured to limit rotation of the hub  56  by contact with abutment surfaces  70 . As such the stopper plates  74  may include projections  94  extending outwardly from an outer periphery of the stopper plates  74 . In one embodiment, the stopper plates  74  have four projections  94 . In the home position each of the projections  94  contacts an abutment surface  70  on a respective wing  66  or protrusion  72 . In one embodiment, the stopper plates  74  are shaped to be 180 degrees rotationally symmetric about the rotation axis A that passes through the central opening of the stopper plates  74 . The rotational symmetry may be apparent from  FIG. 7 . 
     With reference to  FIG. 5 , the parts of the handle return module  44  may be held together by a retaining ring  96  (see  FIG. 6 ) clipping into a retention groove  98  provided near the lock-side of the hub  56 . Movement of the components along the rotation axis A relative to the housing  54  may be limited on the handle-side by the flange  60  of the hub  56  and on the lock-side by the retaining ring  96 . The stopper plates  74  may be limited in their positioning along the rotation axis A between the retaining ring  96  and a lip  100  of the housing  54 .  FIG. 6  also shows a lock-side recess  102  configured to accept a portion of the spindle  48  for transferring motion from the hub  56  to the lock  12 . 
       FIG. 7  is a lock-side view of a left-handed handle return module  44 L in the home position. The left-handed handle return module  44 L shown in  FIG. 7  is assembled from the same elements used to create the right-handed handle return module  44 R shown in  FIG. 5  without modifying the construction of any of the individual elements. Comparing the left-handed handle return module  44 L with the right-handed handle return module  44 R, the spring  80  is flipped, e.g. rotated 180 degrees, about a reversing axis R. In the illustrated embodiment, the reversing axis R is a vertical axis. Though not apparent from  FIG. 7 , in some embodiments, the hub  56  may rotated 180 degrees about rotation axis A to convert from a right-handed handle return module to a left-handed handle return module in embodiments where only a single slot  88  is present. While rotating the hub  56  may present an extra step, this extra step may still be advantageous because rotating the hub  56  will align the keyed portion  62  with the proper indicia  64 . Use of the keyed portion  62  and the indicia  64  may help minimize assembly mistakes. 
     Further, comparing the right-handed handle return module  44 R with the left-handed handle return module  44 L, the stopper plates  74  are also flipped. In one example, the stopper plates  74  may be rotated 180 degrees about the reversing axis R. In the embodiment shown, the rotational symmetry of the stopper plates  74  also allows for rotation about a secondary axis S, perpendicular to both reversing axis R and rotation axis A, to achieve the same results of assembling the stopper plates  74  with the housing  54  to change the direction of allowable rotation of the hub  56  relative to the housing  54 . 
       FIG. 8  shows another embodiment, a non-operating or dummy handle return module  44 D, assembled from the same elements used to create the right-handed handle return module  44 R shown in  FIG. 5  and the left-handed handle return module  44 L shown in  FIG. 7  without modifying the construction of any of the individual elements. The dummy handle return module  44 D is an embodiment where the hub  56  is substantially prevented from rotation in either direction relative to the housing  54 . The dummy handle return module  44 D is created by orienting at least a first stopper plate  74 R relative to the housing for providing right-handed operation and orientation at least a second stopper plate  74 L relative to the housing  54  for providing left-handed operation. The combination of these two oppositely oriented stopper plates  74 R,  74 L collectively prevent the hub  56  from rotating relative to the housing  54 . 
     The handle return modules  44  of the present disclosure have been designed to use the same components, assembled in different ways, to create a module for right-handed operation, a module for left-handed operation, and a module for dummy operation. The door hardware  14  may include one or more modules in dummy operation when the door hardware is used on an inactive door of a French door pair. 
       FIGS. 3-8  present an example embodiment only.  FIG. 9  is a lock-side view of a second embodiment of a handle return module  144  assembled for left-handed operation. The stopper plate  174  of this second embodiment includes a single projection  94 . To convert the handle return module  144  to right-handed operation, the stopper plate  174  may be flipped about reversion axis R. A spring  80  may also be provided and similarly flipped as discussed above. Further the handle return module  144  of the second embodiment is also capable of a dummy configuration by flipping the stopper plate  174  about secondary axis S, (see dashed lines in  FIG. 9 ) resulting in the projection  94  rotationally constrained between a protrusion  72  similar to one found in the first embodiment, and a boss  172  extending from the lip  100  of the housing  54 . 
       FIGS. 10 and 11  are handle-side and lock-side perspective views of a housing  254  according to another embodiment. The housing  254  may be more narrow along the rotation axis A than the first housing  54 , to accommodate alternative escutcheon designs. The housing  254  is designed, however, to be assembled into a handle return assembly  44 L.  44 R using the remainder of the components shown in  FIG. 5 , without further modification to components other than between the first housing  54  and the second housing  254 . 
     The housing  254  shown in  FIGS. 10 and 11 , includes optional indicia  264  to help identify the handing of the finished assembly. The housing  254  also includes one or more wings  266  extending therefrom and having mounting apertures  268  formed in the wings  266  for mounting the housing  254  to an escutcheon. As seen in  FIG. 11 , the housing  254  also includes a plurality of projections  272  providing a plurality of abutment surfaces  270 , similar to those discussed above. The housing  254  also includes a pair of notches  286  to selectively accept the radially outer leg of the spring. 
     The operation of the door  10  may now be further described in view of the figures collectively. In many embodiments, the lock  12  may include features that decouple the handles  42 , in other words, rotation of a handle on the interior of the door does not produce rotation of a handle on the outside of the door, and vice versa. These decoupling features may be integral with the lock  12  and are known in the art. The function of the door hardware  14  may therefore be described based on half of the components, either inside or outside of the door  10 . In one embodiment, a handle may be assembled to the handle-side recess  58  of the hub  56 . As a user turns the handle  42  about rotation axis A, the hub  56  is able to rotate within housing  54 . The stopper plate(s)  74  rotate with the hub  56  until the force applied by the user terminates or the stopper plate(s)  74  reach abutment surfaces  70 . Further, a spindle  48  may fit in the lock-side recess  102  of the hub  56  and protect into a portion of the lock  12 . Therefore, as the hub  56  rotates relative to the housing  54 , the spindle  48  may be caused to rotate along with the hub  56 , transferring motion into the lock  12  for ultimate retraction of the latch(s)  22 . While the hub  56  is rotating relative to the housing  54  under the outside force provided by a user, the spring  80  may be wound tighter, storing potential energy that will bias rotation of the hub  56 , handle  42 , and spindle  48  in the opposite direction of rotation biased toward the home position after the user removes an outside force. 
     The structure, function, and use of the handle return cartridges discussed above may translate to several methods of installing door hardware upon a door where the door hardware makes use of the handle return cartridges according to embodiments previously described. Example methods may be described in terms of the following paragraphs: 
     Paragraph A. A method of installing door hardware on a door, the hardware including an interior escutcheon, an exterior escutcheon, a pair of handles, a left-handed handle return cartridge and a right-handed handle return cartridge, the method comprising:
         identifying the proper handle, from the pair of lever-type handles that is appropriate for each escutcheon based on a swinging direction of the door;   identifying the proper handle return cartridge for each escutcheon;   attaching the identified cartridge to the appropriate escutcheon; and   installing the door hardware on the door.       

     Paragraph B. The method of Paragraph A, wherein identifying the proper cartridge comprises:
         selecting the left-handed handle return cartridge for the escutcheon whose respective handle lever points left when facing a handle-side of the escutcheon and   selecting the right-handed handle return cartridge for the escutcheon whose respective handle lever points right when facing a handle-side of the escutcheon.       

     Paragraph C. The method of Paragraph A, wherein attaching the identified cartridge comprises screwing a housing onto a lock-side of the appropriate escutcheon. 
     Paragraph D. The method of Paragraph A, further comprising attaching the proper handle lever to each handle return cartridge. 
     Paragraph E. The method of Paragraph A, wherein installing the door hardware further comprises attaching the escutcheons to the door. 
     Paragraph F. The method of Paragraph E, wherein attaching the escutcheons comprises:
         first positioning the exterior escutcheon relative to the door;   then positioning the interior escutcheon relative to the door; and   then securing the exterior escutcheon to the interior escutcheon with the door therebetween.       

     The assemblies may also be described in view of the following paragraph: 
     Paragraph G. A handle return assembly removably attachable to an escutcheon, comprising:
         a housing to be attached to the escutcheon;   a hub rotatably disposed within the housing for operably connecting an operating handle to a drive spindle;   a torsion spring biasing the hub toward an initial position; and   at least one stopper plate interacting with the housing for limiting rotational motion of the hub relative to the housing,   wherein selectively positioning the at least one stopper plate and the spring relative to the housing provides the assembly with an ability to provide a right-handed operation or a left-handed operation.       

     Although the above disclosure has been presented in the context of exemplary embodiments, it is to be understood that modifications and variations may be utilized without departing from the spirit and scope of the invention, as those skilled in the art will readily understand. Such modifications and variations are considered to be within the purview and scope of the appended claims and their equivalents.