The field of the invention is handlesets for doors.
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.
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).
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.
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.
Thus, there is still a need for improved concealed screw handlesets.
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.
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.
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.
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.
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'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.
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.
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.
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.
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.
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.
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).
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.
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.
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.
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.
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.
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.
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.
This application claims the benefit of priority to U.S. Provisional Application No. 62/278,408, filed Jan. 13, 2016.
Number | Date | Country | |
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62278408 | Jan 2016 | US |