Patent Document

FIELD OF THE INVENTION 
   The present invention relates to a lock assembly. In particular, the invention relates to an apparatus for retaining a retractor mechanism used to extend and retract a latch of the lock assembly. 
   BACKGROUND OF THE INVENTION 
   Lock assemblies generally include a retractor mechanism attached to a latch or bolt and supported by a chassis mounted in a door. The retractor mechanism extends and retracts the latch to secure access through the door. 
   SUMMARY OF THE INVENTION 
   Typically, the retractor mechanism must be assembled and installed while building-up a chassis to support the lock assembly in the door. Likewise, removal of the retractor mechanism requires the disassembly of the chassis as well. The present invention provides an innovative design of a retainer apparatus for the retractor mechanism. The retainer apparatus of the invention allows the retractor mechanism to be pre-assembled before or after the chassis has been assembled. Manufacturers and installers of lock assemblies will find this innovative design less cumbersome when assembling and/or dissembling a lock assembly. 
   In one embodiment, the invention provides a retractor retainer apparatus for a retractor mechanism that extends and retracts a latch. One embodiment of the retainer apparatus is a clip that is operable to hold the retractor mechanism and the latch. The clip includes a back component having a first and second end, the back component having at least one post for mounting a spring to bias the retractor mechanism, a first side component having a first end connected to one end of the back component, and a second side component having a first end connected to the other end of the back component, wherein the first and second side components provide a bearing surface to slide the latch retractor mechanism, and a first front component connected to the second end of the first side component, and a second front component connected to the second end of the second side component, the first and second front components angled inward to form a narrowed gap that retains the latch retractor mechanism and allows extension and retraction of the latch to secure access through the door. 
   In another embodiment, the invention provides a door lock assembly for securing a door, the lock assembly including a retractor mechanism to linearly extend the latch to a locked position and to retract the latch to an unlocked position, a chassis to support the lock assembly in the door, and a retainer apparatus to hold the retractor mechanism, the retainer apparatus having a back component having at least one post for mounting at least one spring to bias the retractor mechanism, a first and a second side component each having one end connected to each end of the back component, said first and second side components providing a bearing surface for moving the retractor mechanism, a first and a second front component connected to the other ends of the first and the second side components, the front components angled inward to form a narrowed gap, wherein the retainer apparatus retains the retractor mechanism in the chassis. 
   Briefly summarized, the retractor retainer apparatus is a clip having a back component, a pair of side plate components, and a pair of front plate components that retains a retractor mechanism for extending and retracting a latch. The retainer apparatus allows the retractor mechanism to be pre-assembled, where this sub-assembly is ready for installation or connection to a partially or completely pre-assembled chassis of a lock assembly. One embodiment of the clip is a single formed piece that includes a back component having at least one post for mounting a spring to bias the retractor, side components to provide a bearing surface to slide the retractor for the latch, and front components angled inward to retain the retractor and engage the latch. A plurality of prongs extend from the clip to hold the clip to the chassis of the lock assembly. Manufacturers will find the sub-assembly of the retractor mechanism less cumbersome and time consuming when assembling and/or disassembling the lock assembly. 
   As is apparent from the above, it is an aspect of the invention to provide a retainer apparatus for a latch retractor mechanism that secures access through a door. Other features and aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of a lock assembly with a retractor mechanism and a retractor retainer apparatus. 
       FIG. 2  is a perspective view of the retainer apparatus. 
       FIG. 3  is a perspective view of the retractor mechanism and retainer apparatus. 
       FIG. 4  is a perspective view of the retainer apparatus and retractor mechanism connected to a chassis. 
   

   DETAILED DESCRIPTION 
   Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. 
     FIG. 1  illustrates a perspective view of a lock assembly  4  that includes a latch apparatus or retractor assembly  6 . One embodiment of the retractor assembly  6  includes a retractor or retractor mechanism  8  retained in a retainer apparatus  10 . 
     FIG. 2  illustrates one embodiment of the retainer apparatus  10  for retaining the retractor mechanism  8 . As illustrated in  FIG. 2 , the retainer apparatus  10  includes a retainer clip having a back component  15 , a first  20  and a second  25  side component, and a first  30  and a second  35  front component. In one embodiment, the back component  15 , first  20  and second  25  side components, and first  30  and second  35  front components are machined-formed from a single metal plate (e.g., steel plate). In an alternative embodiment, the components of the retainer apparatus  10  can be created separately and inter-connected using any suitable means (e.g., spot-welded, soldered, etc.) known to those in the art. 
   As shown in  FIG. 2 , one embodiment of the back component  15  is a curvilinear-shaped metal plate. The curvilinear shape is designed to conform to the overall shape of the lock assembly  4 . In alternative embodiments, the back component  15  can include other shapes (e.g., bends, flat sides, etc.) suitable for the lock assembly  4 . Another embodiment of the back component  15  includes a pair of posts  40  and  45 . As shown in  FIGS. 2 and 3 , the posts  40  and  45  support the retractor mechanism springs  50  and  55 . One embodiment of the posts  40  and  45  are machined stamped or cut out from the back component  15  and angled in a direction inwardly with respect to or from the back component  15 . In another embodiment, the posts  40  and  45  can be separate components attached to the back component  15  using other suitable means (e.g., spot-welded) known to those in the art. In yet another embodiment, the posts  40  and  45  can be stamped or cut out from a portion of the back component  15  and each side component  20  and  25 . The back component  15  also includes a catch spring base  60 . The catch spring base  60  supports a catch spring biased against a catch of the retractor mechanism  8  (discussed later). 
   The first  20  and second  25  sides form the bearing surfaces for sliding the retractor mechanism  8  in a linear direction between an extended and a retracted position. As shown in  FIG. 2 , the first  20  and second  25  side components have one end connected to each end of the back component  15 . One embodiment of side components  20  and  25  are flat plates to support the linear sliding of the retained retractor mechanism  8 . Of course, the shape of the side components  20  and  25  can vary. The first  20  and the second  25  side components are designed to have some elasticity to enable installation of the retractor mechanism  8 . 
   As shown in  FIGS. 2 and 3 , the first  30  and second  35  front components constrain the retractor mechanism  8  against the back component  15  and the bias of the springs  50  and  55 .  FIGS. 2  shows one embodiment of the first  30  and the second  35  front components angled inward with respect to the ends of the first  20  and second  25  side components. The inward-angled front components  30  and  35  form a narrowed gap  65 . The width of the gap  65  is designed to constrain the retractor mechanism  8 , yet allow the extension and retraction of a latch or bolt  70  ( FIG. 1 ) of the retractor mechanism  8 . The first  30  and second  35  front components are also designed with some flexibility for installing the retractor mechanism  8 . 
     FIG. 3  shows a perspective view of the retractor mechanism  8  installed in the retainer apparatus  10 . The retractor mechanism  8  slides along the side components  20  and  25  to extend and retract the bolt  70  ( FIG. 1 ). As shown in  FIG. 3 , one embodiment of the retractor-mechanism  8  includes a first  105  and a second carrier  110 , a pair of retractor bars  115  and  120 , and the pair of springs  50  and  55 . The retractor bars  115  and  120  include a pair of lips  125  and  130  that engage the bolt  70 . Drive shafts  135  and  140  ( FIG. 1 ) include cams (not shown) designed to engage the first  105  and second  110  carriers. When rotating drive shaft  135  to retract the bolt  70 , the cams of the drive shaft  135  engages the first carrier  105 . The rotational force of the drive shaft  135  against the carrier  105  causes the retractor mechanism  8  to slide along the side components  20  and  25  against the bias of the springs  50  and  55 . Under the force of the drive shafts  135  and  140 , the retractor mechanism  8  retracts the bolt  70 . Upon release of the rotational force on the drive shaft  135  and  140 , the springs  50  and  55  bias the retractor mechanism  8  forward toward its original position. Thereby, the retractor mechanism  8  slides to extend the bolt  70 . The drive shaft  140  engages the carrier  110  in a similar manner as the drive shaft  135 . 
   As shown in  FIG. 3 , another embodiment of the retractor mechanism  8  further includes a catch  141 . The catch  141  engages a spring  145  compressed against the catch spring base  60  of the back component  15 , thereby biasing the catch  141  toward an extended position. The catch  141  is operable in holding a plunger bar (not shown) in a locked position. 
     FIG. 4  illustrates a perspective view of a chassis  200  in support of the retractor mechanism  8  and retainer apparatus  10 . In one embodiment, the chassis  200  includes a first  205  and a second  210  side support for the retainer apparatus  10 . As shown in  FIGS. 2 and 4 , the retainer apparatus  10  includes a plurality of prongs  240  for receiving the first  205  and second  210  side supports of the chassis  200 . The prongs  240  can be one or more extensions at each end of a component and is not limiting on the invention. In one embodiment, the back component  15  includes two pairs of back prongs  240   b  and  240   d  that extend past the first  20  and second  25  side components ( FIG. 3 ). Each pair of back prongs  240   b  and  240   d  extends parallel with the ends of the back component  15 . In addition, one embodiment of the front components  30  and  35  include front prongs  240   a  ( FIG. 1) and 240   c  that extend outward in a similar fashion past the first  20  and second  25  side plates. Similar to prongs  240   b  and  240   d  in relation to the back  15 , the front prongs  240   a  and  240   c  extend parallel with each end of the first  30  and the second  35  front plates. The back prongs  240   b  and  240   d  and the front prongs  240   a  and  240   d  are located at opposite ends of the first  20  and second  25  side components and angled inward to receive the first  205  and second  210  side supports of the chassis  200 . One embodiment of the prongs  240   a–d  are machine stamped or cutout from the first  20  and second  25  side components. Of course, the prongs  240   a–d  can be separate components attached using other suitable means (e.g., spot-welded, soldered, etc.) known to those in the art. 
   As shown in  FIG. 4 , the first  205  and second  210  side supports of the chassis  200  include reliefs  250  to receive the prongs  240   a–d  of the retainer apparatus  10 . One embodiment of a relief  250  is a beveled edge at an angle compatible with the angle of the prongs  240   a–d.  Of course, other shapes (e.g., channels) for a relief  250  in the side supports  205  and  210  of the chassis  200  can be used. 
   As shown in  FIGS. 2–4 , the retainer apparatus  10  allows the retractor mechanism  8  to be assembled individually from the build-up of the chassis  200  that supports the lock assembly  4 .  FIG. 2  illustrates one embodiment of the retainer apparatus  10  that is formed from machine pressing a metal plate. An operator pre-assembles the retractor assembly  6  by flexing the side components  20  and  25 , then inserting the retractor mechanism  8  inside the retainer apparatus  10 . Upon unflexing the side components  20  and  25 , the retractor mechanism is constrained. 
   Once the retractor assembly  6  is pre-assembled, the retractor assembly  6  can be inserted or connected to the chassis  200  as shown in  FIGS. 1 and 4 . In one embodiment, the chassis  200  is pre-assembled individually from the retractor assembly  6 . Upon individual assembly of the retractor assembly  6  and the chassis  200 , an operator can insert or slide the assembled retractor apparatus  6 , as shown by arrow  255  in  FIG. 4 , into an aperture  258  formed by the assembled chassis  200 . As described above, the prongs  240   a–d  secure the retractor assembly  6  to the chassis  200 . To disassemble the lock assembly  4 , the retractor assembly  6  can be removed from the chassis  200  without disassembling the retractor mechanism  8  and/or chassis  200  similar to the method for assembly described above. In one embodiment, an operator can slidingly remove the retractor assembly  6  from the reliefs  250  of the chassis  200  without disassembling the chassis  200 . Thereby, the design of the retractor mechanism  8  and retainer apparatus  10  of the invention is more versatile and less cumbersome to assemble and/or disassemble. In another embodiment, the retractor assembly  6  can be slid along the reliefs  250  when assembling the chassis  200  of the lock assembly  4 . 
     FIG. 1  illustrates an exemplary embodiment of a lock assembly  4  with the retractor assembly  6  interconnected through an aperture  258  with an assembled chassis  200 . The chassis  200  includes a first  260  and a second  265  hub having openings for receiving the drive shafts  135  and  140 . The exemplary first hub  260  and second  265  hubs are mounted using screws  270 . Of course, other suitable connection means (e.g., spot-weld, cast, etc.) known in the art can be used. One embodiment of the chassis  200  is comprised of cast metal. Of course, the chassis  200  can be comprised of cast metal and/or one or more other suitable materials (e.g., forged metal, plastic) known in the art of lock assemblies. 
   Thus, the invention provides, among other things, a retractor assembly having a retractor mechanism retained in a retainer apparatus for connection to a chassis of a lock assembly. Various features and advantages of the invention are set forth in the following claims.

Technology Category: 4