Abstract:
An improved concealed screw handleset for a door is described. The handleset assembly has a handleset, a mounting plate, and a face plate. The handleset and mounting plate are fastened together on opposite sides of the door via one or more assembly screws. The assembly screws are inserted from the mounting plate side of the door and are not visible from the handleset side of the door. The faceplate mounts on the mounting plate via two threaded collars. The faceplate completely covers the mounting plate and the assembly screws. In this manner, the handleset assembly provides a concealed screw design that is very easy to assemble and install. In other aspects, the mounting plate has a rotatable stem for mounting a turn-piece. The stem has one or more catches to hold the turn-piece in different positions.

Description:
[0001]    This application claims the benefit of priority to U.S. Provisional Application No. 62/278,408, filed Jan. 13, 2016. 
     
    
     FILED OF THE INVENTION 
       [0002]    The field of the invention is handlesets for doors. 
       BACKGROUND 
       [0003]    The background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art. 
         [0004]    Various handleset assemblies for doors and are known. Such handlesets are used to open and close doors, lock doors, and provide an ornamental aspect. Handleset assemblies typically include one or more handles (e.g., knob, lever) that actuate a latch-bolt assembly, and a turn-piece and deadbolt cylinder that actuate a deadbolt assembly. Examples of handlesets, locksets, and latchsets are disclosed in: USD0501389, USD0501634, USD0571183, USD0579302, USD0579760, USD0642044, USD0697385, USD0739203, USD0743237, US2831336, US4453753, US4502720, US4526256, US4674776, US5259652, US5351513, US5611227, US5765412, US5810402, US6401932, US6802546, US7934754, US8176761, US8424935, US6401932, US8939477, US20030041633, US20060138788, US20080054651, US20080079267, US20100257906, US20110314878, US20120055213, US20130139563, US20140047878, US20140159392, US20150345175, US20150015003, GB2154439, GB2189860, GB2296033, GB2314583, GB2315806, GB9125230, GB9711989, JP08026694, WO2005116377, and WO2015168679. Examples of commercially available handlesets include: Omnia Industries Entrance Handlesets (www.omniaindustries.com/image/data/catalogs/omnia_entrance_handleset_catalog_2014.pdf), Baldwin Hardware Estate Prestige Handlesets (www.baldwinhardware.com/products/category/door-hardware/estate/entrance), Schlage Entry Handlesets (www.schlage.com/en/home/products/products-handlesets.html), Fusion Entry Hardware and Deadbolts (www.fusionhardware.com/en/products/handlesets.html), and Emtek Assa Abloy Tubular Entrance Handlesets and Locksets (www.emtek.com/tubular-entrysets). 
         [0005]    All extrinsic materials cited herein, including patent publications and commercial references, are incorporated by reference to the same extent as if each individual reference was specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply. 
         [0006]    Some of the preferred characteristics of a handleset assembly include: (i) an attractive and stylish design, (ii) easy to assemble and install, (iii) minimal-to-no wobble in the handle(s), (iv) no lever sagging, (v) minimal number of components, and (vi) inexpensive. In many instances, a concealed screw handleset is preferred to provide an attractive appearance. While others have attempted to provide a concealed screw handleset, such prior efforts have produced complicated assemblies that often suffer from wobble and/or lever sag. 
         [0007]    Thus, there is still a need for improved concealed screw handlesets. 
       SUMMARY OF THE INVENTION 
       [0008]    The present invention provides apparatus, systems, and methods in which a handleset assembly provides a concealed screw appearance and design. As used herein, the term “concealed screw” means there are no visible assembly screws when the handleset is installed on a door, although tiny set screws may still be visible but not readily noticeable. Contemplated handleset assemblies include a handleset (either a one piece design or a two piece design), a mounting plate, and a faceplate. The handleset and mounting plate are fastened together on opposite sides of the door via one or more assembly screws. The assembly screws are inserted from the mounting plate side of the door and are not visible on the handleset side. Once the handleset and mounting plate are fastened together, the faceplate is then fastened to the mounting plate using two threaded collars. The faceplate completely covers the mounting plate and the assembly screws. In this manner, the handleset assembly provides a concealed screw design that is very easy to assemble and install. 
         [0009]    In one aspect of the inventive subject matter, the mounting plate has two holes with internal threads that mate with the two threaded collars. A rotatable stem extends from the first threaded hole and is sized and dimensioned for attaching a turn-piece. A rotatable spindle through-hole is disposed in the center of the second threaded hole and is sized and dimensioned to receive, and mechanically engage with, a spindle via one or more set screws. The rotatable spindle through-hole is coupled with a torsion spring to provide a resistance to rotation. One end of the spindle is sized and dimensioned to engage a handle. The rigid coupling of the spindle with the through-hole (via the set screws) and the torsion spring help to reduce and or eliminate handle wobble (also referred to as play or wiggle). The mounting plate also has one or more assembly screw holes that are sized and dimensioned to receive one or more assembly screws, which are used to fasten the mounting plate to the handleset. 
         [0010]    In another aspect of the inventive subject matter, the handleset has an opening that is sized and dimensioned to receive a deadbolt cylinder assembly. The deadbolt cylinder assembly has a key hole on an outward facing surface (i.e., away from the door) and a tail piece extending from an inward facing surface (i.e., towards the door). The deadbolt cylinder assembly houses a locking mechanism that turns the tail piece when a key is inserted into the key-hole and rotated. The tail piece is sized and dimensioned to mechanically engage a slot or opening in the rotatable stem of the mounting plate. The inward facing surface of the deadbolt cylinder assembly also has one or more threaded assembly screw holes for attaching the mounting plate. 
         [0011]    The handleset also includes a handle and a thumb piece on an outward facing surface, and a chassis member on an inward facing surface. The chassis member is functionally coupled with the thumb piece and has a spindle opening that is sized and dimensioned to receive the spindle. The spindle opening also has one or more set screws for rigidly coupling the chassis member to the spindle, and is coupled with a torsion spring that provides rotational resistance. The thumb piece and chassis member are configured to rotate the spindle when the thumb piece is pressed. The chassis member has one or more threaded assembly screw holes for attaching the mounting plate. 
         [0012]    In yet another aspect of the inventive subject matter, the faceplate has a first opening and a second opening separated by the same distance of separation as the mounting plate&#39;s two threaded holes. When the faceplate is fastened to the mounting plate the threaded holes on the mounting plate align with the openings on the face plate, such that the rotatable stem extends through the first opening and the spindle extends through the second opening. Once the two collars are used to fasten the faceplate to the mounting plate, a turn-piece is attached to an end of the stem and a handle is attached to an end of the spindle. The turn-piece and handle are sized and dimensioned to completely cover the first and second collars, respectively. 
         [0013]    The inventive subject matter also provides apparatus, systems, and methods in which a mounting plate for a concealed screw handleset assembly includes a rotatable stem with catches (e.g., grooves, channels, indentations, cavities, openings, etc.) that mate with a spring-loaded ball-catch. As the stem is rotated the ball-catch is pressed into the catch to temporarily lock the stem in place. The stem can then be rotated further until the ball-catch engages the next catch. The catches on the stem can be separated by predetermined radial distances (e.g., every 90 degrees, every 180 degrees, etc.) depending upon the configuration of the deadbolt assembly. In this manner, a turn-piece attached to the rotatable stem can be held securely in an unlocked orientation/position and a locked orientation/position, thereby preventing turn-piece wobble (or play or wiggle). In other aspects, a pin can be used to engage a catch on the rotatable stem, preventing the stem from rotating. In this manner, a turn-piece on a double door can be converted into a dummy (i.e., non-functional) turn-piece. 
         [0014]    One should appreciate that the disclosed subject matter provides many advantageous technical effects including providing a concealed screw handleset assembly. The disclosed subject matter also provides a handleset assembly that is easy to assemble and install, has a convertible dummy turn-piece, and reduces turn-piece wobble and handle wobble. 
         [0015]    Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
         [0016]      FIG. 1  is an exploded view of a handleset assembly and a door. 
           [0017]      FIG. 2  is a perspective view of the door of  FIG. 1 . 
           [0018]      FIG. 3  is a rear perspective view of the handleset in  FIG. 1 . 
           [0019]      FIG. 4 a    is a rear perspective view of the deadbolt cylinder in  FIG. 1   
           [0020]      FIG. 4 b    is a front perspective view of the deadbolt cylinder in  FIG. 1 . 
           [0021]      FIG. 5 a    is an exploded rear perspective view of the mounting plate in  FIG. 1   
           [0022]      FIG. 5 b    is a front perspective view of the mounting plate in  FIG. 1 . 
           [0023]      FIG. 5 c    is a rear perspective view of the mounting plate in  FIG. 1 . 
           [0024]      FIG. 5 d    is a rear plan view of the mounting plate in  FIG. 1 . 
           [0025]      FIG. 5 e    is a front plan view of the mounting plate in  FIG. 1 . 
           [0026]      FIG. 5 f    is a side view of the mounting plate in  FIG. 1 . 
           [0027]      FIG. 5 g    is a close-up top, rear, perspective view of the mounting plate of  FIG. 1 . 
           [0028]      FIG. 6 a    is a rear perspective view of the stem in  FIG. 5   a.    
           [0029]      FIG. 6 b    is a front perspective view of the stem in  FIG. 5   a.    
           [0030]      FIG. 6 c    is a side view of the stem in  FIG. 5   a.    
           [0031]      FIG. 6 d    is a rear plan view of the stem in  FIG. 5   a.    
           [0032]      FIG. 6 e    is a front plan view of the stem in  FIG. 5   a.    
           [0033]      FIG. 7 a    is a front perspective view of the spindle through-hole in  FIG. 5   a.    
           [0034]      FIG. 7 b    is a rear perspective view of the spindle through-hole in  FIG. 5   a.    
           [0035]      FIG. 7 c    is a side view of the spindle through-hole in  FIG. 5   a.    
           [0036]      FIG. 7 d    is a front plan view of the spindle through-hole in  FIG. 5   a.    
           [0037]      FIG. 7 e    is a rear plan view of the spindle through-hole in  FIG. 5   a.    
           [0038]      FIG. 8 a    is an exploded front perspective view of the mounting plate and faceplate in  FIG. 1 . 
           [0039]      FIG. 8 b    is an exploded rear perspective view of the mounting plate and faceplate in  FIG. 1 . 
           [0040]      FIG. 8 c    is a rear perspective view of the mounting plate and faceplate in  FIG. 1 . 
           [0041]      FIG. 8 d    is a side view of the mounting plate and faceplate in  FIG. 1 . 
           [0042]      FIG. 9  is an exploded view of the spindle in  FIG. 1   
           [0043]      FIG. 10  shows a rear plan view of the turn-piece in  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION 
       [0044]    The following discussion provides example embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C, or D, even if not explicitly disclosed. 
         [0045]      FIG. 1  shows an exploded view of a handleset assembly  100  and a door  200 . Handleset assembly  100  comprises a handleset  101 , a deadbolt cylinder  102 , a deadbolt assembly  103 , a latch-bolt assembly  104 , a spindle  105 , a mounting plate  106 , assembly screws  107 , a face plate  108 , a first collar  109 , a first washer  110 , a turn-piece  111 , a second collar  112 , a second washer  113 , a handle  115  (with a set screw  114 ), a washer  116 , a handleset screw  117 , and a cover  118 . Handleset assembly  100  has a concealed crew design, in which assembly screws  107  are hidden once assembly  100  is installed on door  200 . Each of the components of assembly  100  will now be described in more detail. 
         [0046]      FIG. 2  shows a perspective view of door  200 . Door  200  has a first major surface  201 , a second major surface  202 , and a first minor surface  203  (e.g., an edge surface). Surface  203  has a first blind-hole  204  (e.g., a first edge bore) and a second blind-hole  205  (e.g., a first edge bore). Blind-hole  204  is sized and dimensioned to receive deadbolt assembly  103  and blind-hole  205  is sized and dimensioned to receive latch-bolt assembly  104 . 
         [0047]    Door  200  also has a first cross through-hole  206  (e.g., a cross bore) that perpendicularly intersects with blind-hole  204  and a second cross through-hole  207  (e.g., a cross bore) that perpendicularly intersects with blind-hole  207 . First cross through-hole  206  is sized and dimensioned to receive deadbolt cylinder  102 . Second cross through-hole  207  is sized and dimensioned to receive a chassis member  302  on handleset  101 . In addition, door  200  has a third through-hole  208  sized and dimensioned to receive handleset assembly screw  117 . 
         [0048]      FIG. 3  shows a rear perspective view of handleset  101 . Handleset  101  has an opening  301  sized and dimensioned to receive deadbolt cylinder  102 . Handleset  101  also has a chassis member  302 . Chassis member  302  has a spindle hole  306  that is sized and dimensioned to receive, and mechanically engage, spindle  105 . Chassis member  302  also has two threaded screw holes  307 , which are sized and dimensioned to mate with assembly screws  107 . Handleset  101  additionally comprises a thumb-piece  303  that actuates chassis member  302  and spindle  105 . More specifically, pressing thumb-piece  101  down causes spindle  105  to rotate. Finally, handleset  101  has a handle  304  for opening door  200 , and a threaded opening  305  for fastening handle  304  to door  200 . 
         [0049]      FIG. 4 a    shows a rear perspective view of deadbolt cylinder  102 .  FIG. 4 b    shows a front perspective view of deadbolt cylinder  102 . Deadbolt cylinder  102  has a key hole  401  that is sized and dimensioned to receive a key. Deadbolt cylinder  102  also has a cylindrical housing  402  that houses a locking mechanism configured to rotate tail piece  404  when a key is inserted into key hole  401  and rotated. Tail piece  404  extends from the rear of cylindrical housing  402  and has a cross section that mechanically engages opening  603  in stem  600 . Cylindrical housing  402  has an annular flange  403  that is sized and dimensioned to stop deadbolt cylinder  102  from being inserted completely through opening  301 . Cylindrical housing  402  has a cylindrical shape, however non-cylindrical shapes are also contemplated. 
         [0050]      FIG. 5 a    shows an exploded rear perspective view of mounting plate  106 . The upper end of mounting plate  106  comprises a rotatable stem  600  that is inserted into opening  501  and held in place with clip  502 . Chimney housing  503  houses a catch  504 , spring  505 , and set screw  506 . Ball  504  is sized and dimensioned to engage indentations in the surface of stem  600 . Adjusting set screw  506  will increase or decrease the force of ball  504  against stem  600 . 
         [0051]    The lower end of mounting plate  106  comprises a rotatable spindle through-hole  700  that is inserted into opening  507  and held in place by clip  508 . Clip  508  also hold torsion spring  509  and cover bracket  510  to the rear surface of mounting plate  106 . The spring constant and torsional resistance of spring  509  can be selected (or replaced with a different spring) depending on the configuration for handle  115  (e.g., knob vs. lever). Spring  509  provides a resistance to the rotation of spindle through-hole  700 . Spindle through-hole  700  has an opening that is sized and dimensioned to receive spindle  105 . Spindle through-hole  700  has to opposing set screws  511  that engage two opposing grooves on spindle  105  (e.g., groove  901 ). 
         [0052]      FIG. 5 b    shows a front perspective view of mounting plate  106 . The upper end of mounting plate  106  has two assembly screw holes  512  on opposite sides of stem  600 . The lower end of mounting plate  106  has two set screws  513  on opposite sides of spindle through-hole  700 . Assembly screw holes  5512  and  513  are sized and dimensioned to receive assembly screws  107 . 
         [0053]      FIG. 5 c    shows a rear perspective view of mounting plate in  106 . 
         [0054]      FIG. 5 d    shows a rear plan view of mounting plate  106 . 
         [0055]      FIG. 5 e    shows a front plan view of mounting plate  106 . 
         [0056]      FIG. 5 f    shows a side view of mounting plate  106 . 
         [0057]      FIG. 5 g    shows a close-up top, rear, perspective view of mounting plate  106 . Set screw  506  can be adjusted from this angle to increase or decrease the force on ball  504 . 
         [0058]      FIG. 6 a    shows a rear perspective view of stem  600 .  FIG. 6 b    shows a front perspective view of stem  600 .  FIG. 6 c    shows a side view of stem  600 . Stem  600  is an elongated member with a longitudinal axis of rotation. Stem  600  has an annular flange  601  that is sized and dimensioned to stop stem  600  from completely passing through opening  501  in mounting plate  106 . Stem  600  also has a radial groove  602  sized and dimensioned to receive ball  504 . Ball  504  travels around groove  602  as stem  600  rotates. Stem  600  has an opening  603  through its center. Opening  603  has a cross section that is sized and dimensioned to receive, and mechanically engage with, tail piece  404  on deadbolt cylinder  102 . When a user inserts a key in key hole  401  and rotates the key, tail piece  404  rotates, which rotates stem  600  and turn-piece  111 . 
         [0059]      FIG. 6 d    shows a rear plan view of stem  600 . Stem  600  has four longitudinal grooves  604  that are spaced apart by a radial distance (e.g., 90 degrees). As stem  600  rotates 360 degrees, ball  504  travels around groove  602  and snaps into each of the plurality of longitudinal grooves  604  every 90 degrees. When ball  504  falls into grooves  604 , stem  600  latches in place. Grooves  604  help turn-piece  111  and stem  600  to stay in their open position and closed position without wobbling or play or sagging over time. 
         [0060]      FIG. 6 e    shows a front plan view of the stem  600 . The front end of stem  600  has a cross sectional shape that mechanically engages opening  1000  in turn-piece  111  (see  FIG. 10 ) so that stem  600  and turn-piece  111  rotate together. Turn-piece  111  also has a set screw  111   a  to rigidly fasten turn-piece  111  to stem  600 . 
         [0061]      FIG. 7 a    shows a front perspective view of the spindle through-hole  700 . Spindle through-hole  700  is sized and dimensioned to fit inside of, and removably couple with, opening  507 . Spindle through-hole  700  is held in place by clip  508 . Spindle through-hole  700  also has an opening  701  extending longitudinally from the front end to the back end. Opening  701  is sized and dimensioned to receive a spindle. Spindle through-hole  700  has a threaded opening  702  extending radially through the cylindrical body of spindle-hole  700 . Opening  702  is sized and dimensioned to receive a set screw. Tightening a set screw in opening  702  when a spindle is disposed in opening  701  locks the spindle in place and helps to prevent lever sag and wobble. 
         [0062]      FIG. 7 b    shows a rear perspective view of the spindle through-hole  700 . The rear end of spindle through-hole  700  has a groove extending radially through the cylindrical body of spindle-hole  700 .  FIG. 7 c    shows a side view of the spindle through-hole  700 .  FIG. 7 d    shows a front plan view of the spindle through-hole  700 .  FIG. 7 e    shows a rear plan view of the spindle through-hole  700 . 
         [0063]      FIG. 8 a    shows an exploded front perspective view of the mounting plate  106  and faceplate  108 .  FIG. 8 b    is an exploded rear perspective view of the mounting plate  106  and faceplate  108 . These exploded views show the order in which the components are assembled to construct mounting plate  106  and faceplate  108 . 
         [0064]      FIG. 8 c    shows a rear perspective view of the mounting plate  106  coupled with faceplate  108  in an assembled state.  FIG. 8 d    shows a side view of the mounting plate  106  and faceplate  108 . 
         [0065]      FIG. 9  shows an exploded view of the spindle  105 . Spindle  105  has a first elongated member  901  rotatably coupled with a second elongated member  902 . Elongated member  901  has two opposing longitudinal grooves  903  (the second groove is not visible from the perspective of  FIG. 9 ). Grooves  903  are sized and dimensioned to engage with set screws on handle  115  and spindle through-hole  700 . Spring-loaded ball catch  905  (e.g., detent) is spaced apart from protrusions  903  by a distance that is substantially equal to, or slightly larger than, the length of spindle through-hole  700 . Ball catch  905  retracts in a flush position when spindle  105  is inserted into through-hole  700 . Protrusions  903  are sized and dimensioned to prevent spindle  105  from being inserted further into through-hole  700 . Protrusions  903  and ball catch  905  straddle through-hole  700  and keep spindle in place (e.g., on mounting plate  106 ) during assembly. 
         [0066]      FIG. 10  shows a rear plan view of turn-piece  111 . Turn-piece  111  has an opening  1000  that is sized and dimensioned to mechanically engage the end of stem  600 . 
         [0067]    From a methods perspective, the inventive subject matter includes a method of installing a concealed screw handleset. In one aspect, the concealed screw handleset comprises a faceplate having a first opening and a second opening spaced apart by a first distance; a mounting plate having a first threaded hole and a second threaded hole spaced apart by a second distance that is substantially equal to the first distance; a rotatable stem extending from the center of the first threaded hole and having a first longitudinal groove; a spindle through-hole sized disposed in the center of the second threaded hole and sized and dimensioned to receive a spindle; a first collar sized and dimensioned to fit in the first opening of the faceplate and having threads that mate with the first threaded hole; and a second collar sized and dimensioned to fit in the second opening of the faceplate and having threads that mate with the first threaded hole. 
         [0068]    The method comprises the steps of: (i) installing the mounting plate onto a first major surface of a door such that the rotatable stem and spindle through-hole are aligned with a first through-hole and a second through-hole, respectively, on the door; (ii) fastening the faceplate to the mounting plate and to the first major surface of the door by (a) aligning the first opening and second opening of the faceplate with the first threaded hole and second threaded hole, respectively, of the mounting plate; (b) inserting the first collar through the first opening of the faceplate from an outward facing surface of the faceplate, and threading the first collar to the first threaded hole of the mounting plate; and (c) inserting the second collar through the second opening of the faceplate from the outward facing surface of the faceplate, and threading the second collar to the second threaded hole of the mounting plate. 
         [0069]    In some embodiments, the step of installing the mounting plate onto a first major surface of a door comprises: (i) inserting a tailpiece of a deadbolt cylinder into a key hole in the center of the rotatable stem of the mounting plate from a second major surface of the door; (ii) fastening the deadbolt cylinder to the mounting plate with one or more assembly screws; (iii) inserting the spindle into the spindle through-hole; (iv) placing a chassis member of a handleset onto an end of the spindle from the second major surface of the door; and (v) fastening the chassis member to the mounting plate with one or more assembly screws. 
         [0070]    In another aspect of some embodiments, the method further comprises the steps of: (i) attaching a turn-piece to the stem from the outside surface of the faceplate, wherein the turn-piece is sized and dimensioned to completely cover the first collar; and (ii) attaching a handle to an end of the spindle from the first major surface of the door, wherein the handle is sized and dimensioned to completely cover the second collar. 
         [0071]    As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise. 
         [0072]    Also, as used herein, and unless the context dictates otherwise, the term “coupled to” is intended to include both direct coupling (in which two elements that are coupled to each other contact each other) and indirect coupling (in which at least one additional element is located between the two elements). Therefore, the terms “coupled to” and “coupled with” are used synonymously. 
         [0073]    Thus, specific compositions and methods of concealed screw handleset assembly have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the disclosure. Moreover, in interpreting the disclosure all terms should be interpreted in the broadest possible manner consistent with the context. In particular the terms “comprises” and “comprising” should be interpreted as referring to the elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps can be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced.