Multi-point exit door lock and method of installation

Abstract

A multi-point exit door lock and method of installing same, the door lock including main lock and upper and lower lock modules. a push type panic bar, lock bolts associated with each of the lock modules, and a pull-type cable of predetermined length having its ends fixed to the main lock module and to each of the upper and lower lock modules, whereby pushing the panic bar opens all lock modules. The method of installing the new lock includes a template which is temporarily mounted to the exit door and rotated to successive positions for automatically and accurately marking all the drill holes for mounting all the lock modules at relative distances apart corresponding to the predetermined distances between them pre-established by the cables of predetermined length fixedly attached to the various lock modules.

Description

While the invention has been described in conjunction with several embodiments, it is to be understood that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, this invention is intended to embrace all such alternatives, modifications, and variations which fall within the spirit and scope of the appended claims.

D. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

For convenience and clarity in describing these embodiments, similar elements or components appearing in different figures will have the same reference numbers.

FIGS. 1 and 2 show the new exit door lock 10 mounted on exit door 12, front surface 12A of door 12, the principal components of lock 10 being main lock module 14, top lock module 16, bottom lock module 18, top cable 16A, bottom cable 18A, protective channels 16B, 18B, panic bar or paddle 20, main lock module deadbolt 22 and top and bottom lock bolts 24, 26.

FIGS. 3 and 4 show schematically how pushing force F in the direction of arrow 21 causes axial or outward motion of panic bar 20 toward inner surface 12A of door 12. This force is applied to motion translation mechanism 23 which applies pulling forces F1, F2 and F3 to the lock bolts 22, 24 and 26 respectively. The mechanism shown in FIGS. 3 and 4 is known in the prior art, causing an internal element to slightly rotate because of the helical thread 23A on post 23B. Many alternative mechanisms are possible to produce pulling/withdrawing force on the lock bolts, including solenoids, other electrical, magnetic, hydraulic or mechanical systems.

One currently used motion and force translation mechanism is shown schematically in FIG. 5 where plate 28 is caused to rotate a few degrees by outward movement of a panic bar 20. Rotary plate 28 has pins 34-37 situated around its circumference and coupled to downstream cable and bolt components, as follows.

As seen in FIG. 5 pin 36 is coupled to cable 16A, so that clockwise rotation of plate 28 in the direction of arrow 38 pulls cable 16A to position 16A′, which through top lock module 16 withdraws top bolt 24 from its extended and locked position. This bolt is spring biased to said locked position by spring 27. Similarly, pin 34, on rotation of plate 28 pulls cable 18A to position 18A′, thence withdrawing spring-biased bottom bolt 26 via bottom lock module 18. Pin 35 (via a link not shown) withdraws bolt 22. Finally, pin 37 optionally couples to an alarm system for notifying a central or other office that this door has been opened. FIG. 5 further shows a bellcrank 42 in upper lock module 16 to drive top bolt 24.

FIG. 4 shows in more detail how cable 16A engages bellcrank 42 situated within top lock module housing 16. Bellcrank arm 43 is fixedly coupled to the top end of cable 16A which pulls bellcrank 42 counterclockwise. This moves bellcrank arm 44 counterclockwise which pulls and withdraws top bolt 24. The bottom lock module operates in substantially the same way.

As described earlier, and as illustrated in FIGS. 1 and 6, cables 16A and 18A are strong and essentially non-stretchable under the loads associated with this lock. Accordingly, when cables 16A, 16B are extended to be straight and taut, top and bottom lock modules 16, 18 will be at the exact predetermined distances D1,D2 respectively from main lock module 14. Thus, when the three lock modules are properly mounted in pre-drilled mounting holes (this to be described later), cables 16A, 18A will be straight and taut, and all bolts 22, 24, 26 will withdraw smoothly and reliably whenever panic bar 20 is pushed.

As described above, the new exit door lock 10 comprises main and top and bottom lock modules 14, 16, 18 and cables 16A, 18A, bolts 22, 24, 28 coupled to respective lock modules, panic bar 20 and motion translation members within each of the lock modules. Further, as described, cables 16A, 18A have predetermined fixed length with ends fixed to respective lock modules. The materials and manufacturing methods for making these components of lock 10 are well known in the prior art, with strength and environmental conditions affecting the selection of materials.

The second aspect of the present invention is the new method of installation of lock 10 as described herein. A principal element required in the new method is marking template 50 seen in FIG. 7 and in FIGS. 11, 13, 14 and 15. Template 50 in FIG. 7 includes drill holes and reference edges, as follows. Edges 51, 52 correspond to vertical and horizontal positioning reference lines on the door, to be described later. Hole 53 is a pivot hole about which template 50 rotates; holes 54-57 (defining trapezoidal pattern 54P) are for bolts to mount main lock module housing door 12; holes 58-59 are for bolts to mount the anti-pry plate 15 (see FIG. 2) on the outside surface of door 12 generally opposite main lock module 14; and holes 60, 61 are for bolts to mount top and bottom modules 16, 18.

The new method of installation proceeds as follows. Per FIG. 9, door 12 is closed onto door frame 70, door 12 being shown as outside the inner edges 71, 72 of frame 70 so that the door can pivot outward when opened. With door 12 closed as shown a vertical line 73 is marked on the door.

Per FIG. 10, horizontal line 74 is mark at a predetermined elevation E, which in this preferred embodiment is forty-five inches up from the floor. The space 75 shown by diagonal lines below and to the left of lines 73 and 74 is where template 50 will be positioned.

Per FIG. 11, template 50 is positioned at area 75, and a pivot hole is marked by a pencil or other marker inserted through hole 53 in the template onto door surface 12A. Per FIG. 12, template 50 is removed, a hole 53H is drilled into door 12 at the mark from template hole 53.

Per FIG. 13, template 50 is re-positioned onto area 75, and a screw is driven through hole 53 into the newly drilled hole. With template temporarily held in this horizontal position, per FIG. 13, holes 54-57 and holes 58-59 are marked through template 50 onto door 12; then per FIG. 14, template 50 is rotated clockwise upward and holes 60, 61 are marked for top lock module 16, and then per FIG. 15, template 50 is rotated about pivot screw 53 to again mark holes 60, 61 this time for bottom lock module 18. The steps of FIGS. 14 and 15 are illustrated more clearly in FIG. 8. Obviously, the sequence of positions of template 50 can be varied in any way. Per FIG. 16, with template 50 removed, all the marked holes are drilled to provide appropriate size mounting holes. From holes 53, 54-57, 58-59 and 60-61 in template 50 have been drilled corresponding holes 53H-61H in door 12.

Per FIGS. 17-19, lock modules 14, 16, 18 are bolted to door 12 via the respective holes that were drilled, at which time cables 16A, 18A are extended straight. Also, protective channels 16B, 18B are attached to cover, conceal and protect cables 16, 18. Per FIG. 19, strike plate 80 is mounted to the door frame and recess holes or additional strike plates are added adjacent top and bottom lock modules 16, 18 to the door frame. Other final and typical and conventional installation details are conducted as required.

A key aspect of the new lock is the pre-assembly of main and remote lock modules 14, 16, 18 with cables 16A, 18A of predetermined fixed lengths, with ends of cables 16A, 18A secured to the various lock modules at the time of manufacture, so that the installer receives a lock assembly of main and remote lock modules that requires no finding, analyzing and assembling of principal components. A key aspect of the new method of installation is the use of the new template 50 which is rotated to various positions for automatically and accurately locating all relevant drill holes of the separate lock modules. In the installation method illustrated the door frame establishes the easy-to-use reference line for the template used to locate all the mounting holes.

It should be apparent to a person of ordinary skill in the art that there exist a variety of mechanisms for converting the outward motion of the panic bar into forces to withdraw the various lock bolts, including solenoids, various electrical motors, hydraulics, etc. Also, the panic bar, while typically being a “push-out” type frequently required by regulations, could also be “push-down” or other type, and furthermore could be actuated in a variety of other ways.

Although the best mode for carrying out the present invention has been described in the foregoing detailed description and illustrated in the accompanying drawings, it will be understood that the invention is not limited to the embodiments enclosed, but is capable of numerous rearrangements, modifications and substitutions of steps and elements without departing from the spirit of the invention. Accordingly, the present invention is intended to encompass such rearrangements, modifications and substitutions of steps and elements as fall within the scope of the appended claims.

Claims

1. A multi-point lock for use with an exit door that is mountable on a door frame and is moveable between closed and open positions, said multi-point lock comprising: a. a main lock module comprising a main housing mountable on said exit door, a main lock bolt carried by said main housing and movable between its locked position where it engages said door frame and its unlocked position for allowing said exit door to open, and main drive means on said main housing for moving said main lock bolt between its locked position and its unlocked position,b. a first remote lock module comprising a first remote housing mountable on said exit door, a remote lock bolt carried by said first remote housing and movable between its locked position where it engages said door frame and its unlocked position for allowing said exit door to open, and a first remote drive means on said first remote housing for moving said first remote lock bolt between its locked position and its locked position,c. a push-type panic bar or paddle that is coupled to said main drive means, mountable on said exit door and moveable from its closed to its opened position which activates said main drive means to drive said main lock bolt to its open position,d. a first pull-type cable having opposite near and remote ends permanently fixed to said main and first remote drive means respectively, said first cable having pre-determined length whereby said first cable, when extended axially, establishes a pre-determined distance between said main and first remote housings,e. whereby said panic bar, when moved from its closed to its opened position, drives said main drive means to move said main lock bolt to its unlocked position and at the same time, when said first cable is extended axially, applies tension to said first cable whose remote end pulls and thereby drives said first remote drive means to move said first remote lock bolt to its unlocked position, so that said exit door can be opened.

2. A multi-point lock according to claim 1, further comprising a second remote lock module having a second remote housing, a second lock bolt and second drive means, and a second pull-type cable with its near and remote ends permanently fixed to said main and second remote drive means respectively, said second cable having pre-determined length whereby said second cable, when extended axially, establishes a pre-determined distance between said main and second remote housings, said main drive means, when moved to its opened position, applying tension to both said first and second cables whose respective remote ends pull and thereby drive said first and second remote drive means to move said first and second remote lock bolts at the same time to their respective unlocked positions.

3. A multi-point lock according to claim 1 further comprising a second remote lock module having a second remote housing, a second lock bolt and second drive means and a second pull-type cable with its near and remote ends permanently fixed to said first and second remote drive means respectively, said second cable having pre-determined length whereby said second cable, when extended axially, establishes a pre-determined distance between said first and second remote housings, and said main drive means, when moved to its opened position, applies tension to both said first and second cables whose respective remote ends pull to thereby drive said first and second remote drive means to move said first and second remote lock bolts at the same time to their respective unlocked positions.

4. A multi-point lock according to claim 1 wherein said exit door has opposite inner and outer side surfaces and is pivotably mountable in said door frame to move in an outward direction from its closed position to its open position, and wherein said main and first remote lock modules are mountable on said inner side surface of said exit door.

5. A multi-point lock according to claim 2 wherein said main lock module drive means has upper and lower parts and said first and second cables have respective near ends attached to said upper and lower parts respectively of said main drive means.

6. A multi-point lock according to claim 4 wherein said panic bar is spaced apart from said inner side surface of said exit door and is movable in an outward direction toward said inner side surface of said exit door.

7. A multi-point lock according to claim 2, wherein said exit door has opposite inner and outer side surfaces and is pivotably mountable in said door frame to move in an outward direction from its closed position to its open position, and wherein said main and first remote lock modules are mountable on said inner side surface of said exit door, and wherein said main drive means comprises a plate mounted for rotation about an axis extending transversely of said drive means inner side of said exit door, said plate having top, bottom, left and right side parts, said top part engaged to said near end of said first cable, said right side part coupled to the main lock bolt, said bottom part coupled to said near end of said second cable, and said left side part coupled to said panic bar, whereby pushing of said panic bar causes rotation of said plate which causes said top and bottom parts as they rotate to apply tension to said first and second cables and to drive said first and second remote drive means to unlock said remote lock bolts, rotation of said plate also simultaneously driving and unlocking said lock bolt of said main lock.

8. A multi-point lock according to claim 2, wherein said upper and lower cables have equal length and said upper and lower modules are situated equidistant from said main lock assembly.

9. A multipoint lock adapted to be mounted on an exit door that is adapted to be mounted on a door frame, where said exit door is movable from its closed position to its open position, said lock comprising: a. a main lock module and first and second remote lock modules, each of said lock modules having a housing, a lock bolt movable in its housing, and drive means to move said lock bolt between its closed and open positions, each of said lock bolts having an end part for locking engagement with said door frame,b. two pull-type cables, each having near and remote ends where said near of each cable is permanently fixed to said main lock drive means and said remote end of each cable is permanently fixed to one of said remote lock drive means, each of said cables having a predetermined length such that there will be a corresponding predetermined distance between said main and said two remote lock modules when said multi-point lock is mounted on an exit door with said cables extended to be generally straight,c. said main lock module further comprising an activation element coupled to said main lock drive means and movable between its closed and open positions,d. whereby, in said multi-point lock, when mounted on an exit door with said cables extended to be generally straight and said lock bolts in their locked positions engaged to said door frame, movement of said activation means from its closed to its open position moves said main lock drive means which simultaneously (a) moves said main lock bolt to its open position, and (b) applies tension to both of said cables which causes said two remote drive means to move their remote lock bolts to move to their respective open positions, so that said exit door can open.

10. A multi-point lock according to claim 9, wherein said exit door is pivotably movable in an outward direction from its closed position to its open position.

11. A multi-point lock according to claim 10, wherein said exit door is pivotable about a generally vertical axis, and said remote lock modules are mountable respectively above and below said main lock module, and wherein all said lock bolts are movable transversely of said vertical axis.

12. A multi-point lock according to claim 9, wherein said activation element is push-type panic bar adapted to be mounted on said exit door, said panic bar having a locked position where it is spaced from said door and being movable in said outward direction to its open position for driving said drive means of said main lock module to its open position which drives said lock bolts of all said lock modules to their respective open positions.

13. A multi-point lock according to claim 9, wherein said first and second cables are of equal predetermined length so that said upper and lower lock modules will each be spaced from said central lock module by the same predetermined distance when mounted on said exit door with said cables extended straight.

14. A multi-point lock according to claim 9, wherein said main lock module drive means is a rotatable element having upper and lower parts coupled to said near ends of said upper and lower cables respectively, and has left and right parts coupled to said panic bar and said lock bolt respectively, so that movement of said panic bar drives said element to rotate, and said element when rotated drives all of said locking bolts at the same time.

15. A multi-point lock according to claim 9, wherein said activation element comprises a push-type panic bar that is movable generally axially between its closed and open positions, coupled with a motion translation member (MTM) that converts said generally axial motion to rotary motion, whereby said MTM is coupled to said main lock bolt and to said near ends of said cables, and said generally axial motion of said push bar rotates said MTM and drives said lock bolts to their open positions.

16. A multi-point lock according to claim 9, wherein in said main lock module said main lock bolt is a dead bolt, and in each of said remote lock modules said lock bolt is spring biased to its locked position.

17. In combination, a multi-point lock according to claim 9 and an exit door that has opposite inner and outer sides and is pivotable in a door frame when pushed in an outward direction from its closed to its open position, said inner side having central, upper and lower parts; said lock mounted on said inner side with said main lock module mounted on said central part and said upper and lower lock modules mounted on said upper and lower parts and respectively spaced apart from said central lock module said predetermined distance, with said first and second cables of said predetermined length extended in a generally straight configuration between said main lock module and said remote lock modules respectively.

18. A method for rapid installation of a multi-point lock on an inside surface of an exit door having top, bottom and intermediate parts and a locking edge opposite the hinge edge, comprising the steps: a. providing a multi-point lock comprising a main lock module and upper and lower lock modules each of which is coupled to said main lock module by a pull-type cable of predetermined length which establishes a predetermined distance between said main and remote lock modules when said cables are extended in a generally straight configuration,b. establishing on said inside surface of said exit door a pivot point that is intermediate said top and bottom parts of said door and near the locking edge of said door, andc. providing a marking template having opposite near and remote ends, a pivot point near said near end and a pattern of holes for said remote lock modules near said remote end and at a predetermined distance from said pivot point,d. positioning said marking template with its pivot point to coincide and pivot with respect to said pivot point of said door,e. pivoting said marking template upward and downward, in any order, and at each of said positions marking said pattern of holes on said door and drilling said holes,f. marking and drilling mounting holes for said main lock module adjacent said pivot point, andg. positioning said main and remote lock modules adjacent their respective mounting hole patterns and with said cables extended axially to said predetermined distance, and attaching said lock modules via said hole patterns to said exit door.

19. A method for rapid installation on an inside surface of an exit door according to claim 18 wherein said marking template further comprises an additional pattern of mounting holes generally near said near end for said main lock module, said method comprising the further step, before or after marking and drilling said remote lock module holes, of pivoting said marking template to a generally horizontal position and marking said additional set pattern of mounting holes on said door and drilling said holes.

20. A method of installation of a multi-point lock according to claim 9, where said exit door will have sets of mounting holes respectively for said main and remote lock modules which sets are spaced apart distances corresponding to said predetermined lengths of said cables when they are extended straight, comprising the steps: a. providing a marking template in the form of a plate having near and remote ends, said template having inward of said near end a pivot point, and having (a) in the vicinity of said pivot point a pattern of holes corresponding to a pattern of holes required for mounting said main lock module to said exit door, and (b) in the vicinity of said remote end a pattern of holes corresponding to a pattern of holes required for mounting said remote lock modules to said exit door,b. establishing a pivot point on said inner surface of said exit door at an elevation and distance from the edge of the door corresponding the desired location of said main lock module,c. temporarily pivotally securing said template via its pivot point onto said exit door at its pivot point,d. in any selected sequence performing steps (1), (2), (3): (1) positioning said template generally vertically upward and marking via said template mounting holes for one of said remote lock modules and then drilling said mounting holes in said exit door,(2) positioning said template generally vertically downward and marking via said template mounting holes for the other of said remote lock modules and then drilling said mounting holes in said exit door, and(3) positioning said template generally horizontally and marking via said template and then drilling said mounting holes for said main lock module,e. removing said template from said exit door,f. positioning said main and remote lock modules to overlie said respective mounting holes therefor and then securing said lock modules to said exit door by fastening means joining said lock modules to their respective mounting holes.