Patent Publication Number: US-9404294-B1

Title: Astragal with adjustable length shoot bolt drive linkage

Description:
FIELD OF THE INVENTION 
     The invention generally relates to locks for double doors, and more particularly relates to an astragal for securing a swinging door panel in a closed position. 
     BACKGROUND 
     Exterior entryways of modern homes and buildings often include cooperating pairs of swinging doors commonly referred to as double doors or French doors. Such doors include an inactive swinging door panel, and an adjacent active swinging door panel. The sets of doors may swing inwardly into the structure (so-called “inswing” doors), or may swing outwardly from the structure (so-called “outswing” doors). The inactive door panel typically includes a generally T-shaped astragal mounted along the entire extent of its non-hinged vertical edge. As used herein, the term “astragal” generally means an elongated member attached to and substantially coextensive with the non-hinged vertical edge of one of a pair of swinging double doors. In a conventional arrangement, an astragal is mounted along the non-hinged vertical edge of an inactive door panel, and provides a stop against which a cooperating active door panel strikes when both door panels are closed. 
     In its simplest form, an astragal consists of a single length of wooden molding attached along the non-hinged edge of an inactive door panel by screws, nails, or the like. Such simple astragals serve no role in fixing an inactive swinging door panel in a closed position in a doorway. Instead, special unrelated locking hardware is required for that purpose. Such locking hardware can be internally mounted within specially formed pockets or recesses within the housing of the inactive door panel or the astragal. Such pockets or recesses must be specially formed in the edge of the door by routing, milling, chiseling, or the like. The locking hardware typically includes independently operable top and bottom shoot bolts which are received in specially drilled bores in the top and bottom of the inactive door panel proximate to the door panel&#39;s non-hinged vertical edge. When extended, the top and bottom shoot bolts selectively engage aligned pockets or holes in the top jamb and doorsill of the associated doorway, thereby fixing the inactive door panel in a closed position. When retracted, the top and bottom shoot bolts permit the inactive door panel to swing open. Both the top and bottom shoot bolts typically are actuated by either a slide or lever mechanism either integral with the shoot bolts or installed along the non-hinged vertical edge of the inactive door panel. 
     Some modern astragals for inactive door panels include vertically moveable top and bottom shoot bolts disposed in a flush-mounted elongated housing. One such astragal is described in U.S. Pat. No. 6,491,326 to Endura Products, Inc., for example. Like the simple astragal described above, the housing of such locking astragals is surface-mounted along the non-hinged vertical edge of an inactive door panel, and provides a stop for a cooperating active door panel. When the inactive panel is closed and the top and bottom shoot bolts are vertically extended, the top and bottom shoot bolts are respectively received in pockets or holes in the top jamb and doorsill of the associated doorway, thereby fixing the inactive panel in a closed position. In order to permit the inactive panel to be opened, the top and bottom shoot bolts can be selectively retracted from their associated pockets or holes in the doorframe. The top and bottom shoot bolts can be vertically extended and retracted by a lever or slide actuating mechanism disposed within the housing. Unlike shoot bolt mechanisms that must be internally installed within specially formed recesses or pockets in a door, such locking astragals can be removably installed relatively easily on a substantially planar external surface or surfaces of an inactive door panel. 
       FIG. 1  illustrates a typical double door entryway with an astragal. The entryway  11  includes an entryway frame or casing defined by spaced apart vertical jambs  12  and  13  and a horizontal head jamb or header  14 . A threshold and sill assembly  16  spans the bottom of the jambs  12  and  13  to complete the entryway frame. A normally inactive door  17  is hinged to the left hand (as seen from the outside of the entryway) jamb  12  and a normally active door  18  is hinged to the right hand jamb  13 . Of course, the normally inactive door just as well can be mounted to the right hand jamb with the normally active door mounted to the left-hand jamb. An astragal  19  is mounted to and extends along the vertical inside edge of the normally inactive door  17 . The astragal  19 , which historically is made of wood but that can be made of metal or other materials, has a generally T-shaped cross section and provides a vertically extending stop against which the active door  18  can close. Flush bolts (not visible in  FIG. 1 ) usually are slidably disposed at the top and bottom of the astragal and are extendable into the head jamb  14  and the threshold and sill assembly  16  to secure the normally inactive door  17  in its closed position. In this way, the normally inactive door, which is opened only occasionally, is secured in its closed position to provide a solid stop for the normally active door and to provide security against a would-be thief. A strike plate  21  and a deadbolt strike  22  are mounted to the inside edge of the astragal  19  and are aligned to receive the latch and deadbolt of the normally active door when closed in the usual way. Weather stripping (not visible) typically is provided along the stop provided by the astragal  19  to seal against drafts and blown rainwater when the normally active door is closed against the stop. 
     SUMMARY 
     The inventors have determined there is a need for an astragal with shoot bolts whose separation can be adjusted. Particularly, there is a need for an astragal that can be adjusted to the height of the door on which it will be installed. 
     While modern locking astragals can be removably installed to external surfaces of an inactive door panel, these astragals must be provided in several lengths to accommodate the variety of doorway heights found in the marketplace. The internal locking assemblies used to control the shoot bolts have conventionally been prefabricated based on the height of the door onto which the astragal is going to be installed, resulting in a fixed distance between the top and bottom shoot bolts in their respective extended and retracted positions. Any attempt to substantially shorten the astragal would be impeded by the rigid drive bars used to extend between the actuator, located generally near the middle of the astragal, and the shoot bolts on each end. Generally a lever actuator is in a fixed location and the drive bars are a discrete length. Shortening these locking astragals would therefore require complete disassembly, cutting of the parts and reassembling. 
     Thus, embodiments of the present disclosure include an adjustable length astragal having a housing with an upper shoot bolt and a lower shoot bolt positioned adjacent opposite ends of the housing. An actuator is attached to the housing, connected to and configured to simultaneously extend or retract the upper and lower shoot bolts. An adjustable connection assembly is provided between the actuator and at least one of the shoot bolts, where the connection assembly adjusts the distance between the actuator and the respective shoot bolt in each of the shoot bolt&#39;s extended and retracted positions. 
     Further embodiments of the present disclosure include selectively removable interlocking links for use in the adjustable length astragal. The links comprise a body having a front side, a back side, a first end surface, a second end surface, and a rotational axis passing through each of the end surfaces. A pair of tabs extends from the first end surface, offset from the rotational axis. A front clamping pocket is formed on the front side, and a back clamping pocket is formed on the back side. Rotation of the body by 90 degrees or less about the rotational axis R interlocks one link with an adjacent link such that each tab of the pair of tabs engages a respective one of the front and back clamping pockets. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a conventional French door entryway including a conventional astragal. 
         FIG. 2  is an exposed-side view of the assembled astragal according to embodiments of the present disclosure. 
         FIG. 3A  is an exploded view of an astragal assembly according to embodiments of the present disclosure. 
         FIG. 3B  is an exploded view of a shortened embodiment of the astragal of  FIG. 3A . 
         FIG. 3C  is a detailed view of the astragal of  FIG. 3A  above cut-line A. 
         FIG. 3D  is a detailed partial-assembled view of the astragal of  FIG. 3C  between cut-lines B. 
         FIG. 4A  is a top front perspective view of a link according to a first embodiment thereof. 
         FIG. 4B  is a bottom rear perspective view of a link according to the first embodiment thereof. 
         FIG. 4C  is a front view of a link according to the first embodiment thereof. 
         FIG. 4D  is a rear view of a link according to the first embodiment thereof. 
         FIG. 4E  is a top view of a link according to the first embodiment thereof. 
         FIG. 4F  is a bottom view of a link according to the first embodiment thereof. 
         FIG. 5A  is a top front perspective view of a link according to a second embodiment thereof. 
         FIG. 5B  is a bottom rear perspective view of a link according to the second embodiment thereof. 
         FIG. 5C  is a front view of a link according to the second embodiment thereof. 
         FIG. 5D  is a rear view of a link according to the second embodiment thereof. 
         FIG. 5E  is a top view of a link according to the second embodiment thereof. 
         FIG. 5F  is a bottom view of a link according to the second embodiment thereof. 
         FIG. 6  is a cross-sectional view of the assembled astragal of  FIG. 2  through line VI-VI. 
     
    
    
     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. 
     One embodiment of a locking astragal  100  for an inactive door panel is shown in  FIG. 2 . As shown in  FIG. 2 , the astragal  100  can include an elongated housing  102  defining a longitudinal axis L. The housing  102  may be an extrusion of substantially constant cross section, or may be formed by other known methods. The housing  102  positions an upper shoot bolt assembly  150  at an upper end thereof and a lower shoot bolt assembly  160  at a lower end. A shoot bolt actuator  122  can be provided for selectively, and simultaneously, extending and retracting the shoot bolts of the shoot bolt assemblies  150 ,  160  relative to the ends of the housing  102 . In the embodiment illustrated, the shoot bolt actuator  122  is a lever-type actuator generally known in the art. 
     At least one strike plate  120  can be positioned along the housing  102  to receive respective latches from a cooperating active door panel (not shown). The astragal  100  may also include a dead bolt plate for receiving a deadbolt from a cooperating active door panel. One or more housing trim plates  128  can be provided between the various exposed components (actuator  122 , strike plates  120 , dead bolt plate, and shoot bolt assembles  150 ,  160 ) to provide the exposed side of the astragal  100  with a finished appearance. These trim plates  128  may be snap-fit to the exposed side of the astragal housing  102 . In a preferred embodiment, the strike plates  120  and the optional dead bolt plate can be adjustable along the length of the housing  102  to ensure proper alignment with respective latch bolts. 
     Further details of the astragal  100  can be seen in the exploded views shown in  FIGS. 3A-3C  and the partial exploded view in  FIG. 3D . An upper trim cap  130  can be provided on the upper end of the housing  102 , and a lower trim cap  132  can be provided on the lower end of the housing  102 . The trim caps  130 ,  132  provide the ends of the astragal  100  with a finished appearance. The upper shoot bolt assembly  150  can include an upper shoot bolt  114 , a bolt spring (not shown), and a bolt sleeve  154 . The upper shoot bolt assembly  150  is configured such that the bolt sleeve  154  can extend from the housing  102  to contact a head jamb, and the upper shoot bolt  114  can then extend past the bolt sleeve  154  into the head jamb. Similarly, the lower shoot bolt assembly  160  is substantially similar to the upper shoot bolt assembly  150 , and includes a lower shoot bolt  116 . 
     As should be understood from  FIG. 3A , the upper and lower shoot bolt assemblies  150 ,  160  can be respectively connected to a pair of slide bars  105 ,  110 . The illustrated embodiment uses a pair of slide bars  105 ,  110 , but a single slide bar may be sufficient. The slide bars  105 ,  110  of each pair translate along channels formed along opposite sides of the housing  102 . The slide bars  105 ,  110  translate together as a pair, with the one end of each bar connect ed to the respective shoot bolt assembly. The other end of each slide bar  105 ,  110  is connected to a connection assembly  180  (see  FIG. 3C ). The connection assembly  180  includes a connector  200  and an optional linkage  275 . Particularly, as shown with respect to the lower shoot bolt assembly  160  only the connector  200  is used, and as shown with respect to the upper shoot bolt assembly  150 , the linkage  275  is added. The linkage  275  may include one or more primary links  300  with or without one or more secondary links  400 . Where a linkage  275  is used, the linkage  275  can then connect to a connector  200 . 
     As best seen in  FIG. 3D , the connector  200  comprises a first end  210  configured to connect with links  300 ,  400  of the linkage  275 . As seen in  FIG. 3A  the first end  210  can also connect with the ends of each slide bar  105 ,  110 . The connector first end  210  can be slidably coupled to a connector second end  220  by a rod  230 . The ends  210 ,  220  of the connector  200  may be biased apart by a connector spring  240 . The connector second end  220  is coupled to a drive bar  125  extending from the actuator  122 . The drive bar  125  is also housed in a channel at one side of, and slides along, the housing  102 , similar to the slide bars  105 ,  110 . Use of the actuator  122  translates the drive bar  125  along the housing  102 , which in turn translates the connector  200 , the linkage  275  (if present), the pair of slide bars  105 ,  110 , and the respective shoot bolt assemblies  150 ,  160  to extend or retract the shoot bolts  114 ,  116 . When the upper and lower shoot bolts  114 ,  116  are extended and are engaged in respective openings in a doorframe, the shoot bolts  114 ,  116  fix an inactive door panel, to which the astragal  100  is attached, in a closed position within the doorframe. 
     According to aspects of the present disclosure, the first end  210  of each connector  200  may be indirectly coupled to the slide bars  105 ,  110  by a linkage  275  made up by one or more selectively removable interlocking primary links  300  and secondary links  400 . By increasing or decreasing the number of interlocking links  300 ,  400  between each of the connectors  200  and their respective slide bars  105 ,  110 , the distance between the shoot bolt assemblies  150 ,  160  can be increased or decreased, thereby helping to adapt the astragal  100  to doors of different heights.  FIG. 3A  shows a full length embodiment of the astragal  100  with several links  300 ,  400  installed.  FIG. 3B  shows a shortened length embodiment of the astragal  100  with some of the primary links  300  removed.  FIG. 3C  is a close up of  FIG. 3A  above cut line A. 
     Turning to  FIGS. 4A-4F , several views of an interlocking primary link  300  are shown. The primary link  300  has a body  302  with a pair of end surfaces  303 . The body  302  has a height H 1 , see  FIG. 4C . In one embodiment, H 1  is approximately one-inch. The height H 1  represents an interval by which the distance between the shoot bolt assemblies  150 ,  160  may be adjusted by adding or subtracting one primary link  300 . By reducing H 1 , a more fine adjustment of the astragal length can be achieved. 
     A rotational axis R passes through the body  302  and each end surface  303 . Each primary link  300  is configured to interlock with an adjacent primary link  300  with approximately a 90 degree (quarter-turn) rotation about the rotational axis R. The body  302  may include a limiting wall  305  to prevent more than 90 degrees of relative rotation. Less than 90 degrees of relative rotation may be necessary to interlock adjacent primary links  300 . 
     With respect to the rotational axis R, the body  302  comprises a shaft  304  protruding from one end of the body  302  along the rotational axis R and comprises a recess  306  formed into the body  302  at the opposite end thereof, the recess  306  also being along the rotational axis R. Thus the shaft  304  of a first primary link  300  is configured to reside within the recess  306  of an adjacent primary link  300  when a plurality of primary links  300  are joined together. 
     The body  302  further comprises a pair of wings  308  and  310  extending perpendicular to the rotational axis R. As best seen in  FIG. 4D , the first wing  308  extends a first distance D 1  relative to the rotational axis R and the second wing  310  extends a second distance D 2  relative to the rotational axis R. In the illustrated embodiment D 1 &gt;D 2 . This asymmetric configuration may assist with assembly of the primary link  300  into the housing  102 , but in other embodiments the wings  308 ,  310  may be mirror symmetric across the rotational axis R. The wings  308  and  310  are configured to couple with respective slide bars  105 ,  110 . 
     With respect to the rotational axis R, one end of the body  302  includes a pair of tabs  312 ,  314  offset from the rotational axis R, but extending outwardly from the body  302  along the direction of the rotational axis R. In the illustrated embodiment, the tabs  312 ,  314  extend from the end of the body  302  having the recess  306 . As best seen in  FIG. 4F , the tabs  312 ,  314  are positioned rotationally symmetric to one another with respect to the rotational axis R. In some embodiments, the first tab  312  has a flat abutment surface  316  and the second tab  314  includes a grooved abutment surface  318 , thereby providing a plurality of teeth. Each tab  312 ,  314  also includes a slot  320  formed therein, see  FIG. 4C . Each slot  320  is adjacent to the respective end of the body  302  and extends into each tab  312 ,  314  in a direction toward and perpendicular to the rotational axis R. 
     The body  302  further defines a front side  330  and a back side  332 . The front side  330  may be rotationally symmetric to the back side  332  about the rotational axis R. However, in the illustrated embodiment, the front side  330  is similar to but not exactly rotationally symmetric to the back side  332 . The front side  330  includes a front clamping pocket  334 . The front clamping pocket  334  includes a front clamping surface  336  generally along the front side  330 . The front clamping pocket  334  also includes a front stop wall  338  positioned normal to the front clamping surface  336 , offset from an end of the body  302 . The front clamping pocket  334  also includes a front protrusion  340  extending normal to the front clamping surface  336  positioned adjacent to an end of the body  302 . 
     The front clamping pocket  334  of a first primary link  300  is configured to interlock with the second tab  314  of an adjacent primary link  300 . In the interlocked position, the second tab  314  resides between the front stop wall  338  and the front protrusion  340 , the grooved abutment surface  318  contacts the front clamping surface  336 , which can be oppositely grooved to mesh with the grooved abutment surface  318 , and the front protrusion  340  protrudes into the slot  320 . Engagement between the front protrusion  340  and the slot  320  helps prevent adjacent primary links  300  from separating along the direction of the rotational axis R when the adjacent primary links  300  are interlocked. Therefore interlocked links are able to translate together along the housing  102  in response to use of the actuator  122 . 
     The back side  332  includes a back clamping pocket  344 . The back clamping pocket  344  includes a back clamping surface  346  generally along the back side  332 , a back stop wall  348  generally normal to the back clamping surface  346  and a back protrusion  350  extending normal to the back clamping surface  346 . Therefore the back clamping pocket  344  should be understood to be similar to the front clamping pocket  334 . The back clamping pocket  344  of a first primary link  300  is configured to interlock with the first tab  312  of an adjacent primary link  300 . In the interlocked position, the first tab  312  resides between the back stop wall  348  and the back protrusion  350 , the smooth abutment surface  316  contacts the back clamping surface  346 , and the back protrusion  350  protrudes into the slot  320  of the second tab  314 . Engagement between the back protrusion  350  and the slot  320  helps prevent adjacent links from separating along the direction of the rotational axis R when the adjacent links  300  are interlocked. 
     Turning to  FIGS. 5A-5F , several views of a secondary link  400  are shown. The secondary link  400  includes many of the same features, and represents an additional embodiment, as the primary links  300 . The secondary link  400  has a body  402 , with a second height H 2  (see  FIG. 5C ) defined along the rotational axis R thereof. The second height H 2  is less than the first height H 1  of the primary links  300 . Therefore secondary links  400  may be used to make finer adjustments in the length of the astragal  100 . In one embodiment, H 2  is approximately one-half inch. The secondary link  400  of the illustrated embodiment is configured to be used in combination with primary links  300  because the secondary link  400  shown does not include wings. Therefore the secondary links  400  are not configured to directly connect with the slide bars  105 ,  110 . One skilled in the art would recognize that wings may be added to the secondary links  400  as shown on the primary links  300 , in which case a plurality of secondary links  400  may be used without any primary links  300 . 
     Again, the secondary links  400  have many of the same features as the primary links  300 . Therefore the secondary links  400  also include a shaft  404 , a recess  406 , and a pair of tabs  412 ,  414 . The secondary links  400  also include a front and back side  430 ,  432  each having a clamping pocket  434 ,  444  with an abutment surface, stop wall and protrusion. Each present portion of the secondary links  400  may be understood as substantially similar to related portions of the primary links  300 . However, in the illustrated embodiment, the secondary link  400  is 180 degrees rotationally symmetric around the rotational axis R, while the illustrated primary link  300  was not. 
       FIG. 6  shows a cross-sectional profile of one embodiment of an astragal  100  having a housing  102 . The housing  102  can be configured for attachment along a non-hinged vertical edge of an inactive door panel. An outwardly extending edge portion  117  of the housing  102  provides a stop for a cooperating active door panel. A resilient seal (not shown) can be attached along the edge portion  117  to provide a weather seal between the astragal  100  and an associated swinging active door panel. As seen from  FIG. 6 , the housing  102  provides a first channel  134  along one side thereof, for slidably accommodating the first slide bars  105 . The first channel  134 , and particularly the first slide bars  105 , may be described as having a T-shaped cross-section. The housing  102  also provides a second channel  136  along an opposite side thereof, for slidably accommodating the second slide bars  110 . The second channel  136 , and particularly the second slide bars  110 , may be described as having a J-shaped cross-section. 
     The first channel  134  is spaced from the second channel  136  by a cavity  138 . As seen in  FIG. 6 , the profile of the primary link  300  (and the secondary link, though not shown) is configured to correspond with the cross-section of the cavity  138 . The corresponding shapes allow the links  300 ,  400  to slide along the length of the astragal  100 , but also limit rotation of each link  300 ,  400  about their rotational axis R. Rotation is particularly limited once the links  300 ,  400  are installed within the housing  102  and the cavity  138  is closed by trim plates  128 . 
     Referring back to  FIG. 3D , connection of the primary links  300  to the slide bars  105 ,  110  is now further described. The first, T-shaped slide bars  105  include an aperture  106  formed there through. The aperture  106  is formed proximate to an end of each of the first slide bars  105 . The second, J-shaped slide bars  110  include at least one notch  111  formed in an edge thereof, where the notches  111  are also proximate to the end of the second slide bars  110 . 
     In the illustrated embodiment, a primary link  300  is connected to each of the slide bars  105 ,  110  by first inserting the first wing  308  through the aperture  106 , and then fitting the second wing  310  into the notch  111 . As shown, the wings of the end most link  300  of the linkage  275  are used to connect with the slide bars  105 ,  110 . As should be understood, the ends of the two drive bars  125  opposite the actuator  122  may also include one of an aperture  106  and a notch  111 . The second end  220  of each connector  200  may include wings substantially similar to those of the primary link  300  to couple a respective connector  200  to a respective drive bar  125 . The first end  210  of the connectors  200  may be configured to include clamping pockets substantially similar to those of the primary link  300  in order for the connector  200  to be coupled to a distal one of the plurality of links  300 ,  400  in the linkage  275 . 
     According to some embodiments of the present disclosure, the astragal  100  can facilitate a method of fitting the astragal  100  to doors of varying heights. According to these embodiments, the astragal  100  would be provided with a housing  102  having a length equal to the height of one of the tallest commonly available doors, such as 96-inch tall doors. The astragal  100  as provided could include a plurality of interlocking primary links  300  and secondary links  400  preloaded between respective slide bars  105 ,  110  and connectors  200 , thereby providing the astragal  100  in a ready-to-mount configuration for tall doors. 
     Then, if mounting the astragal  100  to shorted doors is desired, the astragal  100  can be modified without being fully replaced. Avoiding the full replacement, or need for a completely separate astragal  100 , can reduce costs by reducing the need to keep various length astragals in inventory. The process of modifying the astragal  100  to a shorter height can include one or more of the following steps: 
     removing trim plates  128 ; 
     removing the second wing  310  of at least one primary link  300  from the notch  111  of the second slide bar  110 ; 
     removing the first wing  308  of the primary link  300  from the aperture  106  of the first slide bar  105 ; 
     removing a plurality of the primary links  300  and/or secondary links  400  from the chamber  138 ; 
     separating one or more of the links  300 ,  400  from the plurality thereof (i.e., the linkage) to shorten the chain of links  300 ,  400  by the desired amount; 
     removing one or both trim caps  130 ,  132 ; 
     removing one or more bars  105 ,  110 ,  125  from the housing  102 ; 
     cutting one end of the housing  102  to remove the extra length thereof; 
     reassembling the astragal  100 , this time with fewer, if any, links  300 ,  400  between the slide bars  105 ,  110  and the connectors  200 . 
     The above descriptions of preferred embodiments of the invention are intended to illustrate various aspects and features of the invention without limitation. Persons of ordinary skill in the art will recognize that certain changes and modifications can be made to the described embodiments without departing from the scope of the invention. For example, while the invention has been described for use with swinging door panels, a locking system according to the invention can also be applied to casement window panels and casement window frames, or the like. All such changes and modifications are intended to be within the scope of the appended claims.