Patent Application
20140331725
The invention relates to a lock assemblies for a door. More particularly, the invention relates to lock cylinders with end caps for securing a latch operating mechanism to the lock assembly.
Some lock assemblies include a housing and a plug that define respective pin chambers to receive pin pairs that respond to a key inserted in a keyway of the plug. When the correct key is inserted, the plug is rotatable relative to the housing to an unlocked position. The plug rotates an latch operating mechanism that is attached to the end of the plug with an end cap.
Some existing lock assemblies include end caps in the form of a mortise cam that is attached to the plug so that the plug moves the mortise cam between a locked position and an unlocked position to operate a latch. In some lock cylinders the mortise cam is attached to the lock cylinder using a screw. Other lock assemblies use end caps in the form of a cylinder that is attached to the plug to rotatably couple a driver bar to the plug. The driver bar extends from the plug to operate a latch to lock and unlock the door. Typically, the end cap is attached to the plug using a threaded connection between the cylinder and the plug. The plug further includes a spring-biased alignment pin that secures the end cap in a fixed rotational position relative to the plug so that the mortise cam or cylinder is fixed to the plug to rotate with the plug.
Since lock cylinder plugs are typically designed to support both types of end cap attachments, cylinder plug geometries are complicated and difficult to manufacture. In addition, the attachment features on the plug introduce weaknesses that can cause failure. Increased manufacturing time to assemble the end cap with the plug is also caused by the complicated and intricate interfaces created by the screwed and threaded connections. Therefore, additional improvements in the attachment of end caps to lock assemblies is needed.
There is disclosed herein systems, methods and devices relating to lock assemblies for doors. The lock assemblies include an end cap that couples a tail piece, cam or other latch operating mechanism to the plug of the lock assembly so that the latch operating mechanism rotates with rotation of the plug to operate a latch. The end caps include a plug engaging portion that is configured to slidably engage an end cap receiving portion of the plug. In certain forms, the plug engaging portion provides opposite projecting members that are received in respective undercut portions of the plug defined by the end cap receiving portion. The end cap receiving portion include linear wall segments along the undercut portion to provide a keyed relationship between the end cap and the plug. The keyed, interfitted engagement relationship between the end cap and the plug rotatably and axially fixes the end cap to the plug. An alignment pin can extend from the plug and engage the end cap to laterally secure the end cap to the plug.
In addition, methods for assembling the lock assembly discussed above are disclosed. These and other forms, features, embodiments, aspects, advantages, and objects are discussed further below.
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications in the described embodiments, and any further applications of the principles of the invention as described herein are contemplated as would normally occur to one skilled in the art to which the invention relates.
Lock assembly 100 includes a housing 102 and a plug 104 extending along and defining a longitudinal axis 103. Plug 104 is selectively rotatable within the housing 102 using the appropriate key 10 so that plug 104 moves about a rotation axis that is defined by or parallel to longitudinal axis 103. As known in the art, the housing 102 and the plug 104 cooperate with each other to define a shear line along which inner pins 106 and outer pins 108 are aligned to unlock lock assembly 100.
Housing 102 includes a first end 110, an opposite second end 112, a wall 114 extending between ends 110, 112, and a pin portion 116 that projects outwardly from one side of wall 114. The wall 114 is substantially cylindrical and defines a hollow portion 118 that receives the plug 104. The housing 102 is typically fixed relative to the door, and the plug 104 is rotatable relative to the housing 102 within the hollow portion 118 for movement between a locked position and an unlocked position.
The pin portion 116 projects outwardly from wall 114 and includes insertion slots 120 and a cover 122. Pin portion 116 defines a plurality of chambers that at least partially house outer pins 108 and springs 124 in chambers that are closed by cover 122. Inner pins 106 are housed at least partially in chambers of plug 104.
Plug 104 includes a body 124 that is rotatable relative to the housing 102 within the hollow portion 118. The body 124 includes a first end portion 126, an opposite second end portion 128, and an outer surface 130. The first end portion 126 is accessible from the front of the lock assembly 100. The second end portion 128 is accessible from the rear of the lock assembly 100.
Outer pins 108 are configured to move in a first or inward direction into the plug 104, and in a second or outward direction away from the plug 104. Generally, the outer pins 108 extend partially into the respective inner pin chambers 135 when the plug 104 is in the locked position and the appropriate key 10 is not inserted into the key slot 134. The pin portion 116 further includes springs 124 to bias the outer pins 108 inwardly. In other constructions, the outer pins 108 may tend to move inward without the springs 124, such as by gravity. When blade 14 of key 10 is inserted, it contacts and moves inner pins 106 and outer pins 108 in contact with inner pins 106 to align the connection between pins 106 and 108 with the shear line. Thus, key 10 can rotate plug 104 in housing 102, and when key 10 is withdrawn one or more of pins 106, 108 extend across the shear line to prevent rotation of plug 104 in housing 102.
The tail piece 142 is attached to the plug 104 via the end cap 140, and extends along longitudinal axis 103 into the door. The tail piece 142 includes a pin engagement portion 148 and a bar 150 extending from pin engagement portion 148. The pin engagement portion 148 includes at least one pin slot 152 that is generally aligned with the at least one of the pin hole 132 in plug 104 when the tail piece 142 is attached to the plug 104. The bar 150 extends longitudinally from the pin engagement portion 148, and engages the driver mechanism to move the latch between the locked position and the unlocked position.
An alignment pin 154 is disposed in pin hole 132 to laterally secure the plug 104 and the tail piece 142 when plug 104 is positioned on second end portion 128 in its proper position. The alignment pin 154 is an elongated member that includes opposite tapered or reduced-diameter ends 160 that define oppositely facing shoulders 162 of the alignment pin 154. A spring 164 is disposed in the pin hole 132 in which the alignment pin 154 is disposed to bias the alignment pin 154 toward the second end portion 128 of the plug 104. One shoulder 162 of the alignment pin 154 is engaged by the spring 164, and the other shoulder 162 is engaged with an end wall 166 of the end cap 140. End wall 166 extends around and defines a notch 158 and an end wall opening 156. Notch 158 is in communication with and extends radially outwardly from opening 156. The alignment pin 154 projects into notch 158 and engages end wall 166 of the end cap 140 to secure the end cap 140 to the plug 104 by preventing end cap 140 from sliding laterally transversely to longitudinal axis 103 relative to plug 104. Alignment pin 154 also aligns the plug 104, the end cap 140, and the tail piece 142 in a predetermined orientation relative to each other. The alignment pin 154 also assisting in the transfer of rotation of the plug 104 to the tail piece 142 so that the door can be locked and unlocked.
As further shown in
End cap receiving portion 170 includes opposite linear wall segments 174a, 174 that are connected by opposite arcuate wall segments 180a, 180b. The linear wall segments 174a, 174b along undercuts 172 form flats that define a keyed relationship with end cap 140 to ensure end cap 140 is fitted on plug 104 in the proper orientation and to resist rotation of end cap 140 relative to plug 104. Linear wall segments 174a, 174b can also apply torque to end cap 140 for rotation of the tail piece 142 extending from end cap 140. The inner surface of cylindrical wall 144 corresponds to the curvature of the adjacent arcuate wall segment 180b while wall segment 180a resides in lateral opening 146 of end cap 140. Alignment pin 154 is depressed while plug engagement mechanism 168 of end cap 140 is interfitted with end cap receiving portion 170 at second end portion 128 of plug 104 from a lateral direction transverse to longitudinal axis 103. When end cap 140 is fitted on second end portion 128 in a proper final position, alignment pin 154 is released to spring outwardly from plug 104 and into contact with end wall 166 in notch 158. Alignment pin 154 laterally secures end cap 140 to second end portion 128. The end cap 140 can be removed by depressing alignment pin 154 to allow end cap 140 to slide laterally relative to plug 104.
End cap 240 includes a cam 242 projecting outwardly from a cam body 244. In one embodiment, cam 242 is in the form of a lobe, although other configurations are possible. End cap 240 and cam 242 are rotatable with the plug 104 to transfer rotation from the plug 104 to the mortise chassis. End cap 240 further includes a hole 246 through body 244 that receives alignment pin 154 when end cap 240 is finally positioned on end portion 128 of plug 104.
As shown in
Cylindrical wall 252 forms an inner surface that corresponds to the adjacent curvature of arcuate wall segment 180b while wall segment 180a resides in a lateral opening 256 of wall 252. Lateral opening 256 defines a space between projecting members 250a, 250b. The linear wall segments 174a, 174b of end cap receiving portion 170 provide keyed flats that ensure end cap 240 is fitted on plug 104 in the proper orientation and resist rotation of end cap 240 relative to plug 104. Linear wall segments 174a, 174b can also assisting in applying torque for rotation of cam 242 extending from end cap 240. Alignment pin 154 is depressed while end cap 240 is laterally fitted with end cap receiving portion 170 at second end portion 128 of plug 104. When end cap 240 is properly fitted on second end portion 128, alignment pin 154 can be released to spring outwardly from plug 104 and into contact with the end wall of body 244 via hole 246. The end cap 240 can be removed by depressing alignment pin 154 to allow end cap 240 to slide laterally relative to plug 104.
The end caps 140, 240 are universal among the different lock assemblies. In other words, the end caps 140, 240 are not specific to a particular lock type design and can be used to secure any tail piece or cam member to the plug.
According to another aspect, a lock assembly is provided. The lock assembly includes an elongated housing that extends along a longitudinal axis between a first end and an opposite second end. The elongated housing defines a hollow portion between the first and second ends. The assembly also includes a plug positioned in the hollow portion of the housing. The plug includes an elongate body extending between a first end portion and an opposite second end portion. The body of the plug defines a key slot in the first end portion for receiving a key to rotate the plug relative to the housing. A latch operating mechanism extends from the second end portion of the plug. The lock assembly also includes an end cap configured to couple the operating mechanism to the second end portion of the plug so that rotation of the plug rotates the operating mechanism. The second end portion of the plug is configured to slidably receive the end cap in a keyed orientation from a direction transverse to the longitudinal axis for securement to one another in an interfitted relationship. The interfitted relationship prevents the end cap from moving along and around the longitudinal axis relative to the plug.
According to another aspect, a lock assembly is provided. The lock assembly includes an elongated housing extending along a longitudinal axis between a first end and an opposite second end and a hollow portion is defined between the first and second ends. The assembly includes a plug positioned in the hollow portion of the housing. The plug includes an elongate body extending between a first end portion and an opposite second end portion. The body of the plug defines a key slot in the first end portion for receiving a key to rotate the plug relative to the housing. The plug further defines opposite undercuts in the second end portion that extend transversely to the longitudinal axis. An operating mechanism extends from the second end portion of the plug. The lock assembly also includes an end cap configured to couple the operating mechanism to the second end portion of the plug so that rotation of the plug rotates the operating mechanism. The end cap includes an end wall from which the operating mechanism extends. The end cap further includes a cylindrical wall extending from the end wall and a plug engagement mechanism extending from the cylindrical wall opposite the end wall. The plug engagement mechanism includes opposite projecting members extending from the cylindrical wall that are received in respective ones of the opposite undercuts to axially secure the end cap to the plug.
According to one embodiment, the lock assembly includes an alignment pin housed in the plug. The alignment pin is axially biased into engagement with the end cap in the interfitted relationship with the plug to prevent the end cap from moving transversely to the longitudinal axis relative to the plug. In one refinement, the end cap includes an end wall that defines a hole and the alignment pin is removably engaged to the end cap in the hole. In yet another refinement, the end cap includes an end wall that defines an opening through which the latch operating mechanism extends and a notch along the opening. The alignment pin is removably engaged to the end cap in the notch.
In another embodiment, the end cap includes an end wall, a cylindrical wall extending from the end wall toward the plug, and a plug engagement mechanism extending from the cylindrical wall opposite the end wall. In one refinement, the cylindrical wall defines a lateral opening into the plug engagement mechanism. In a further refinement, the plug engagement mechanism includes a first projecting member and an opposite second projecting member that extend into a space defined by the cylindrical wall. The first and second projecting members are slidably received in undercuts defined by the second end portion of the plug. In yet a further refinement, the first and second projecting members each define a ledge facing the end wall that contact the second end portion of the plug along the undercuts. In another refinement, the second end portion of the plug further defines opposite first and second linear wall segments along respective ones of opposite first and second undercuts. The linear wall segments define the keyed orientation of the end cap relative to the plug. In one refinement, the second end portion of the plug includes opposite arcuate wall segments connecting the first and second linear wall segments to one another.
In one embodiment, the end cap is keyed to the second end portion of the plug so that the end cap can only be engaged to the plug in a predetermined orientation. In one refinement, the keyed engagement of the second end portion of the plug to the end cap prevents the end cap from rotating relative to the plug around the longitudinal axis.
In another embodiment, the assembly includes an alignment pin housed in the plug that is axially biased into engagement with the end cap to prevent the end cap from moving relative to the plug transversely to the longitudinal axis. The end wall of the end cap defines a hole and the alignment pin is removably engaged to the end cap in the hole. In yet another embodiment, the d end cap includes an end wall that defines an opening and a notch along the opening, and the alignment pin is removably engaged to the end cap in the notch.
In a further embodiment, the cylindrical wall defines a lateral opening into the plug engagement mechanism through which the second end portion of the plug is received when the end cap is fitted to the plug. In another embodiment, the operating mechanism includes one of a tail piece with an elongated bar extending from the end cap along the longitudinal axis and a lobe extending outward from the end cap transversely to the longitudinal axis.
According to a further aspect, a method for assembling a lock is disclosed. The method includes positioning an elongated plug in an elongated housing so that a first end of the plug defining a key slot for receiving a key is generally aligned with a first end of the housing and a second end portion of the plug opposite the first end projects outwardly from a second end of the housing; depressing an alignment pin into the plug against a biasing member; sliding an end cap transversely to the longitudinal axis to secure the end cap in an interfitted relationship with the second end portion of the plug to prevent the end cap from rotating relative to the plug and from moving axially relative to the plug; and releasing the alignment pin to engage the end cap with the alignment pin, wherein the end cap couples a latch operating mechanism to the plug so that rotation of the plug relative to the housing rotates the latch operating mechanism.
In one embodiment of the method, the interfitted relationship is defined by undercuts in the second end portion of the plug that slidably receive projecting members of the end cap that extend into an interior space of the end cap.
While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the certain embodiments have been shown and described and that all changes and modifications that come within the spirit of the inventions are desired to be protected. It should be understood that while the use of words such as preferable, preferably, preferred or more preferred utilized in the description above indicate that the feature so described may be more desirable, it nonetheless may not be necessary and embodiments lacking the same may be contemplated as within the scope of the invention, the scope being defined by the claims that follow.
In reading the claims, it is intended that when words such as “a,” “an,” “at least one,” or “at least one portion” are used there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. When the language “at least a portion” and/or “a portion” is used the item can include a portion and/or the entire item unless specifically stated to the contrary.
The present application claims the benefit of the filing date of Provisional Application No. 61/821,925 filed on May 10, 2013, which is incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 61821925 | May 2013 | US |
