Abstract:
An adjustable deadbolt assembly including a deadbolt, a cylinder-connecting portion formed with mounting provisions for mounting thereto a lock cylinder, an actuator formed with a hub connectable to a lock cylinder, the hub being journaled in the cylinder-connecting portion and a link bar that connects the actuator to the deadbolt at at least one of a plurality of attachment points formed on at least one of the deadbolt and the link bar.  
     A method for adjusting an adjustable deadbolt assembly is also disclosed.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates generally to deadbolt assemblies and particularly to an extendable deadbolt, which can extend from one standard size to another, a deadbolt assembly having a pivotable faceplate and a deadbolt assembly suitable for use with doors of varying thickness.  
         BACKGROUND OF THE INVENTION  
         [0002]    Many kinds of deadbolt assemblies are commercially available. Deadbolts are thrown and retracted by means of a key-operated cylinder which passes through a hub of the deadbolt assembly. Turning the key turns the hub, which causes a cam or actuator to throw or retract the bolt. Some deadbolts are operated by a single cylinder, wherein the deadbolt is actuated by a key from outside the door and by a turmpiece from inside the door. Other deadbolts are operated by a double cylinder, wherein the deadbolt is thrown or retracted by a key from both sides of the door.  
           [0003]    Deadbolts are thrown and retracted into a doorpost through a metal plate called a strike. The distance between the strike and the center of the hub is called the backset. In the United States, standard backsets are generally 2.375 inches or 2.75 inches. The throw of the deadbolt varies from one lock to another, with the maximum generally being 1 inch.  
           [0004]    Most deadbolts are fixed at one standard backset or another. However, deadbolts with an adjustable backset are known. For example, KWIKSET manufactures and sells a deadbolt with a helical screw body (for example, its 880 series). By turning the strike, one can change the backset from 2.375 to 2.75 inches, and vice versa. SCHLAGE manufactures a line of deadbolts (B160 Grade 3 deadbolts) wherein the hub can be slid from one end of an elliptical hole to another, thereby adjusting the backset from one standard size to another.  
           [0005]    However, adjustable-backset deadbolts of the art suffer from a drawback of a relatively weak mechanical connection between the deadbolt and the hub end of the assembly. This makes adjustable-backset deadbolts generally unsuitable for high security installations. In addition, the spacing between mounting screws used to mount the key-operated cylinder to the deadbolt assembly are not standard in prior art adjustable-backset assemblies.  
           [0006]    Generally, deadbolt assemblies are not particularly flexible when non standard applications are required. For example, when conventional deadbolt assemblies are mounted on bevel-mounted doors, the faceplates must be specially enlarged and specially aligned to match the particular application. Similarly, when conventional deadbolt assemblies are mounted on doors of non-standard thickness, special hardware must be used.  
         SUMMARY OF THE INVENTION  
         [0007]    The present invention seeks to provide a novel deadbolt with an adjustable backset wherein there is a positive and strong mechanical link at all times between the deadbolt and the hub end of the deadbolt assembly. The deadbolt itself extends all the way to a mounting screw used to mount the key-operated cylinder to the deadbolt assembly. This is in contrast to prior art deadbolt assemblies which have shorter deadbolts. The longer deadbolt provides added strength against break-in attempts. Moreover, in the present invention, unlike the prior art, the spacing between mounting screws used to mount the key-operated cylinder to the deadbolt assembly is standard.  
           [0008]    There is thus provided in accordance with a preferred embodiment of the present invention an adjustable deadbolt assembly including a deadbolt, a cylinder-connecting portion formed with mounting provisions for mounting thereto a lock cylinder, an actuator formed with a hub connectable to a lock cylinder, the hub being journaled in the cylinder-connecting portion, and a link bar that connects the actuator to the deadbolt at at least one of a plurality of attachment points formed on at least one of the deadbolt and the link bar. The attachment points may be notches formed on a periphery of the deadbolt or on the link bar.  
           [0009]    In accordance with a preferred embodiment of the present invention the deadbolt is slidingly disposed in a tube, and the cylinder-connecting portion, the link bar, the actuator and the deadbolt are selectively removable from the tube.  
           [0010]    Further in accordance with a preferred embodiment of the present invention a pin is placed between the tube and the cylinder-connecting portion, the pin being pushable inwards into a hole formed in the cylinder-connecting portion so as to release the tube from the cylinder-connecting portion, thereby permitting withdrawing the cylinder-connecting portion, the actuator, the link bar and the deadbolt from the tube.  
           [0011]    Still further in accordance with a preferred embodiment of the present invention the deadbolt has a length such that the deadbolt extends to one of the mounting provisions when the link bar fits into one of the notches formed on the deadbolt.  
           [0012]    Additionally in accordance with a preferred embodiment of the present invention the mounting provisions are mounting holes spaced from one another corresponding to a spacing between mounting screws of a lock cylinder.  
           [0013]    In accordance with a preferred embodiment of the present invention a strike is attached to the tube wherein a distance, called a backset, between an outer surface of the strike and a center of the hub is defined by the notch in which the link bar is fitted. Preferably the backset varies from about 2.375 inches to about 2.75 inches.  
           [0014]    There is also provided in accordance with a preferred embodiment of the present invention a method for adjusting an adjustable deadbolt assembly including withdrawing the cylinder-connecting portion, the link bar, the actuator and the deadbolt from the tube, moving the link bar from one attachment point to another, and sliding the cylinder-connecting portion, the link bar, the actuator and the deadbolt back into the tube.  
           [0015]    There is also provided in accordance with a preferred embodiment of the present invention a deadbolt assembly including a deadbolt, a tube in which the deadbolt is slidingly disposed including an end through which said deadbolt emerges when extended, and a faceplate pivotably connected to an end of the tube. The deadbolt assembly may be but need not necessarily be an adjustable deadbolt assembly of the type described hereinabove.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0016]    The present invention will be understood and appreciated more fully from the following detailed description, taken in conjunction with the drawings in which:  
         [0017]    [0017]FIGS. 1 and 2 are simplified exploded and pictorial illustrations, respectively, of an adjustable deadbolt assembly constructed and operative in accordance with a preferred embodiment of the present invention;  
         [0018]    [0018]FIG. 3 is a simplified pictorial illustration of a deadbolt in a tube, which forms part of the adjustable deadbolt assembly of FIGS. 1 and 2;  
         [0019]    [0019]FIGS. 4 and 5 are simplified pictorial illustrations of the deadbolt and an actuator in respective relatively short and relatively long backset positions;  
         [0020]    [0020]FIGS. 6 and 7 are simplified sectional illustrations of the relatively short backset position shown in FIG. 4, wherein FIG. 6 is taken along lines VI-VI in FIG. 4 and FIG. 7 is taken along lines VII-VII in FIG. 6;  
         [0021]    [0021]FIGS. 8 and 9 are simplified sectional illustrations of the relatively long backset position shown in FIG. 5, wherein FIG. 8 is taken along lines VIII-VIII in FIG. 5 and FIG. 9 is taken along lines IX-IX in FIG. 8;  
         [0022]    [0022]FIG. 10 is a simplified pictorial illustration of a deadbolt assembly having a pivotably mounted faceplate in accordance with a preferred embodiment of the present invention and illustrating three different orientations of the faceplate;  
         [0023]    [0023]FIG. 11 is an exploded view of part of the deadbolt assembly of FIG. 10, showing a preferred embodiment of pivotably mounted faceplate; and  
         [0024]    [0024]FIG. 12 is an assembled view of the part of the deadbolt assembly shown in FIG. 11. 
     
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0025]    Reference is now made to FIGS.  1 - 9  which illustrate an adjustable deadbolt assembly  10  constructed and operative in accordance with a preferred embodiment of the present invention.  
         [0026]    Deadbolt assembly  10  preferably includes a deadbolt  12  formed with a plurality of notches  14  on a periphery thereof. Two such notches  14  are shown in the illustrated embodiment (FIGS.  4 - 6  and  8 ), but it is appreciated that the invention is not limited to this number of notches. Assembly  10  also preferably includes a cylinder-connecting portion  16  formed with mounting provisions  18  for mounting thereto a lock cylinder  20 . Lock cylinder  20  is shown as a double cylinder, wherein deadbolt  12  is thrown or retracted by a key (not shown) from both sides of a door (not shown). However, it is appreciated that other arrangements, such as a single cylinder, may also be used.  
         [0027]    Mounting provisions  18  are preferably mounting holes  17  and  19  (FIGS.  3 - 5 ) which are spaced from one another corresponding to a spacing between mounting screws  21  of lock cylinder  20  (FIG. 1). It is noted that in the illustrated embodiment, mounting hole  17  is formed as a half hole, and deadbolt  12  is preferably formed with a half hole  15 . As described hereinbelow with reference to FIG. 6, when deadbolt  12  is placed in a short backset position, half holes  15  and  17  form a complete hole.  
         [0028]    An actuator  22  is preferably formed with a hub  24  into which lock cylinder  20  is connected, as is known in the art. Hub  24  is preferably journaled in cylinder-connecting portion  16 . Cylinder-connecting portion  16  may be formed of two halves  16 A and  16 B, secured by a fastener such as a retaining clip  26 , for example (FIGS. 7 and 9). A link bar  28  preferably connects actuator  22  to deadbolt  12 . Link bar  28  is preferably formed with an aperture  30  in which is received a portion of actuator  22 , such as a tongue  32 . An end  34  of link bar  28  is preferably adapted to fit into one of notches  14  formed on deadbolt  12 . Alternatively, as shown in dotted lines in FIG. 4, notches  14  may be formed on link bar  28  and deadbolt  12  may be formed with protrusions  33  which are received in one of the notches formed on link bar  28 . In general, link bar  28  connects actuator  22  to deadbolt  12  at one of a plurality of attachment points formed on either deadbolt  12  or link bar  28 .  
         [0029]    Deadbolt  12  is preferably disposed in a tube  36 . Tube  36  is preferably connected to the rest of assembly  10  by means of a pin  38 , which is preferably spring-loaded by a spring  40 . A strike  42  is preferably attached to tube  36 . The distance (backset) between an outer surface of strike  42  and a center of hub  24  is defined by the notch  14  in which link bar  28  is fitted.  
         [0030]    In order to change the backset of deadbolt assembly  10 , pin  38  is pushed inwards (against spring  40 ) into a hole  44  (FIGS. 4 and 5) formed in cylinder-connecting portion  16  so as to release tube  36  from cylinder-connecting portion  16 . This permits withdrawing and removing cylinder-connecting portion  16 , actuator  22 , link bar  28  and deadbolt  12  from tube  36 , generally in the direction of an arrow  46  (FIGS. 6 and 8). Link bar  28  may now be moved from one of notch  14  to another. If link bar  28  is fitted in the notch  14  closest to strike  42 , then the backset is relatively short (FIGS. 4, 6 and  7 ). Conversely, if link bar is fitted in the notch  14  furthest from strike  42 , then the backset is relatively long (FIGS. 5, 8 and  9 ). Afterwards, cylinder-connecting portion  16 , link bar  28 , actuator  22  and deadbolt  12  are slid back into tube  36 .  
         [0031]    It is noted that deadbolt  12  preferably has a length such that it extends to one of mounting provisions  18  when link bar  28  is adjusted to the shorter backset, as seen best in FIG. 6. In this position, half holes  15  and  17  form a complete hole.  
         [0032]    In accordance with American industry standards, the backset of the present invention preferably varies from about 2.375 inches to about 2.75 inches. Of course, other dimensions are also in the scope of the invention.  
         [0033]    Reference is now made to FIG. 10, which is a simplified pictorial illustration of a deadbolt assembly having a pivotably mounted faceplate in accordance with a preferred embodiment of the present invention and illustrating three different orientations of the faceplate and to FIGS. 11 and 12, which show details of the pivotable mounting of the faceplate.  
         [0034]    As seen in FIGS.  10 - 12 , there is provided a deadbolt assembly  100 , which may be, but need not necessarily be, of the type described hereinabove with reference to FIGS.  1 - 9 . The deadbolt assembly  100  includes inter alia a tube  102  through which a bolt  103  is slidably displaceable.  
         [0035]    In the illustrated embodiment, a forward end  104  of tube  102  is formed with a pair of oppositely disposed apertured lugs  106  and  108  having formed therein respective apertures  110  and  112 . Preferably, the lugs  106  and  108  are positioned such that when the deadbolt assembly  100  is mounted onto a door, apertures  110  and  112  lie along a vertical axis  114 .  
         [0036]    In the illustrated embodiment, a mounting plate  120  is pivotably mounted onto tube  102 , preferably for pivotable mounting about the vertical axis  114  (FIG. 10). Preferably, the mounting plate  120  is formed with mounting lugs  126  and  128  having formed therein respective apertures  130  and  132 .  
         [0037]    A retaining spring  134  having respective engagement ends  136  and  138  is arranged to pivotably retain mounting plate  120  onto tube  102 . End  136  extends through respective apertures  110  and  130  of respective lugs  106  and  126 , while end  138  extends through respective apertures  130  and  132  of respective lugs  108  and  128 , thus defining pivot axles both of which preferably extend along vertical axis  114 .  
         [0038]    A face plate  140 , to which is attached the mounting plate  120 , is readily screwed onto an edge of a door (not shown) by means of mutually alignable screw holes  142  and  144  in the face plate which correspond to screw holes  146  and  148  in the mounting plate  120 .  
         [0039]    It is appreciated that the arrangement of FIGS.  10 - 12  is particularly helpful when mounting a deadbolt assembly on a door, which is hung in a bevel arrangement and ensures that the faceplate  140  is centered relative to the deadbolt. In this way, a deadbolt aperture  150  in the faceplate  140  may be made as small as possible.  
         [0040]    It will be appreciated by persons skilled in the art that the present invention is not limited by what has been particularly shown and described hereinabove. Rather the scope of the present invention includes both combinations and subcombinations of the features described hereinabove as well as modifications and variations thereof which would occur to a person of skill in the art upon reading the foregoing description and which are not in the prior art.