AU2007200720B2 - A mortice lock - Google Patents

Description

S&F Ref: 499499AUD1

AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT Name and Address of Applicant Actual Inventor(s): Address for Service: Invention Title: Gainsborough Hardware Industries Limited, an Australian company, ACN 004 792 269, of 190 Whitehorse Road, Blackburn, Victoria, 3130, Australia Andrey Iliuk Spruson Ferguson St Martins Tower Level 31 Market Street Sydney NSW 2000 (CCN 3710000177) A mortice lock The following statement is a full description of this invention, including the best method of performing it known to me/us:- 5845c(683277_1) A MORTICE LOCK Field of the Invention The present invention relates to a lock and more particularly to a mortice lock which is adapted for recessed installation into the edge of a door or door frame.

The invention has been primarily developed for installation in the aluminium frame of a glass sliding door and will be described with reference to this application. However, it would be appreciated that the invention is not limited to this particular application and is equally suited for installation in other types of doors.

Background of the Invention Numerous types of mortice locks are known. A problem common to most known mortice locks is their inability to be easily re-configured to suit different door backset distances. This requires different models of each lock for each backset distance, which adds to development and inventory cost.

Another problem is a lack of space efficiency of the internal components.

Compactness is vital, especially for short backset distances.

Further, many known mortice locks can only operate in one handle turning direction, which causes operational problems with knobs, as they tend to be used in both directions.

Some mortice locks have the locking cylinder above the handle. This results in keys scratching the handle. Also, the large opening in the housing where the cylinder is fitted, allows sawdust and other debris to fall in to the lock mechanism and cause mechanical failure.

Object of the Invention It is an object of the present invention to substantially overcome or at least ameliorate one or more of the above disadvantages and, in general, to provide a mortice lock with fewer components than known mortice locks -2- Summary of the Invention Accordingly, the present invention provides a mortice lock comprising: a lock housing; a drive shaft adapted to be rotationally driven about an axis by a handle or knob; a hub mounted on the shaft for rotation therewith from a first position towards either a second clockwise position and a third anti-clockwise position, the hub having a pair of spaced apart protuberances; and a drive means adapted for movement relative to the housing, the drive means having a pair of formations and an engaging surface adapted, upon moving, to cause movement in a bolt retraction assembly, wherein clockwise movement of the hub to the second position causes one of the protuberances to abut one of the formations and cause the drive means to move in a first direction and anti-clockwise movement of the hub to the third position causes the other of the protuberances to abut the other of the formations and also cause the drive means to move in the first direction.

In one form, the drive means is mounted for slidable movement relative to the housing.

In another form, the drive means is mounted for pivotal movement relative to the housing and incorporates the bolt retraction assembly therein.

The bolt retraction assembly is preferably moved to retract the bolt regardless of which direction (clockwise or anti-clockwise) the handle or knob is rotated.

The drive means is desirably spring biased in a second direction opposite the first direction and also biases the hub to the first position.

The lock desirably includes a pair of the drive shafts and a pair of the hubs, each mounted on one of the drive shafts, and the drive means contains two pairs of formations, wherein each one of the pairs of formations is adapted to engage each one of the pairs of protuberances when the hubs are in the first position.

In an embodiment, the bolt retraction assembly includes a pivotable latch arm and the drive member engaging surface is a gear rack adapted to engage with a gear portion provided on the latch arm.

In another embodiment, the bolt retraction assembly is an arm pivotally mounted to the lock housing.

Brief Description of the Drawings A preferred embodiment of the invention will now be described, by way of an example only, with reference to the accompanying drawings in which: Fig. 1 is a rear partial perspective view of an assembled mortice lock according to a first embodiment of the invention; Fig. 2 is an exploded view of the lock shown in Fig. 1 in the orientation of Fig. 1; Fig. 3 is a front partial perspective view of the lock shown in Fig. 1; Fig. 4 is an exploded perspective view of the lock shown in Fig. 1 in the orientation of Fig. 3; Fig. 5 is an exploded perspective view of a bolt assembly from the lock of Fig. 1; Figs. 6 and 7 are assembled rear perspective views of the bolt assembly shown in Fig. 5 before and after door closure; Figs. 8 and 9 are partial side and top views respectively of the bolt assembly shown in Fig. 6; Figs. 10 and 11 are partial side and top views of the bolt assembly shown in Fig. 7; Fig. 12 is a partial perspective view of the lock.,shown in Fig. 1 and the bolt assembly shown'in Fig. 5 after door closure; Fig. 13 is an enlarged detailed view of the components shown in Fig. 12; Fig. 14 is a partial perspective view of the lock shown in Fig. 1 and the bolt assembly shown in Fig. 5 before door closure; Fig. 15 is an enlarged detail view of the components shown in Fig. 14; Fig. 16 is a side view of the bolt assembly shown in Fig. 1 with a 23 millimetre backset; Fig. 17 is a modified form of the bolt assembly shown in Fig. 16 with a millimetre backset; Figs. 18, 19 and 20 are side views of the lock shown in Fig. 1 with the hub in first, second and third positions respectively; Figs. 21 and 22 are perspective views and side views respectively of the lock shown in Fig. 1 with the bolt extended; Figs. 23 and 24 are perspective views and side views respectively of the lock shown in Fig. I with the bolt retracted; Figs. 25 and 26 are partial perspective and side views of the bolt assembly and a bolt retraction arm showing the bolt in an extended position; Figs. 27 and 28 are partial perspective and side views respectively of a bolt assembly and a bolt retraction arm showing the bolt at the start of retraction; Figs. 29 to 32 are partial side views of the bolt assembly and a kick off member in various stages of operation; Figs. 33 to 36 are partial perspective views of the bolt assembly kick off member and locking device in various stages of operation; Fig. 37 is a side view of the lock shown in Fig. 1 with the kick off member set in an inactive position; Fig. 38 is an enlarged detailed view of Fig. 37; Fig. 39 is a side view of the lock shown in Fig. 1 with the kick off member set in an active position; Fig. 40 is an enlarged detailed view of Fig. 37; Fig. 41 is an exploded perspective view of the hub locking means of the lock shown in Fig. 1; Fig. 42 is a partially assembled exploded view of the components shown in Fig 41; Fig. 43 is a partial side view of the lock shown in Fig. 1 with the engagement means in an engaged position; Fig. 44 is an enlarged detailed view of Fig. 43; Fig. 45 is a partial side view of the lock shown in Fig. 1 with the engagement means in a disengaged position; Fig. 46 is an enlarged detailed view of Fig. Fig. 47 is a side view of the lock shown in Fig. 43; Fig. 48 is a side view of the lock shown in Fig. Fig. 49 is a rear partial perspective view of an assembled mortice lock according to a second embodiment of the invention; Fig. 50 is an exploded view of the lock shown in Fig. 49 in the orientation of Fig.

49; Fig. 51 is a front partial perspective view of the lock shown in Fig. 49; Fig. 52 is an exploded perspective view of the lock shown in Fig. 51 in the orientation of Fig. 51; Fig. 53 is an exploded perspective view of a bolt assembly from the lock of Fig. 49; Fig's 54 and 55 are assembled rear perspective views of the bolt assembly shown in Fig. 53 before and after door closure respectively; Fig's 56 and 57 are side views of the bolt assembly shown in Fig's 54 and respectively; Fig. 58 is a partial perspective view of the lock shown in Fig. 49 and the bolt assembly shown in Fig. 53 after door closure; Fig. 59 is an enlarged detailed view of the components shown in Fig. 58; Fig. 60 is a partial perspective view of the lock shown in Fig. 49 and the bolt assembly shown in Fig. 53 before door closure; Fig. 61 is an enlarged detailed view of the components shown in Fig. Fig. 62 is side a view of the lock shown in Fig. 49 with a 23 mm backset; Fig. 63 is a modified form of the lock assembly shown in Fig. 62 with a 60 mm backset; Fig's. 64, 65 and 66 are side views of the lock shown in Fig. 49 showing hub operation; Fig's. 67 and 68 are partial perspective and side views respectively of the bolt assembly and a bolt retraction arm showing the bolt in an extended position; Fig's 69 and 70 are partial perspective and side views respectively of a bolt assembly and a bolt retraction arm showing the bolt at the start of bolt retraction; Fig's. 71, 72, and 73 are side views of the lock shown in Fig. 49 showing bolt retraction with a short cam; Fig's. 74, 75, 76 and 77 are side views of the lock shown in Fig. 49 showing bolt retraction and locking bar operation with a medium cam; Fig's. 78, 79 and 80 are side views of the. lock shown in Fig. 49 showing locking bar operation with a long cam; Fig's 81 and 82 are partial and complete side views respectively of the lock shown Sin Fig. 49 configured with an inactive kick-off; SFig's. 83 and 84 are partial and complete side views of the lock shown in Fig. 49 configured with an active kick-off; Fig's 85 and 86 are partial side views of the lock shown in Fig. 49 showing pre and post kick-off operation respectively; Fig's 87 and 88 are exploded and assembled perspective views of the hub locking N- means from the lock of Fig. 49; Fig. 89 is a partial side view of the lock shown in Fig. 49 showing the locking bar engager engaged to the locking bar and disengaged from the lock housing; Fig. 90 is an enlarged detail view of Fig. 89; Fig. 91 is a partial side view of the lock shown in Fig. 49 showing the locking bar engager disengaged from the locking bar and engaged to the lock housing; and Fig. 92 is an enlarged detail view of Fig. 91.

Detailed Description of the Preferred Embodiments Figs 1 to 48 show a first embodiment of a mortice lock 2a which includes examples of the five aspects of the invention. Turning firstly to Figs. 1 to 4, the lock 2a includes first and second key cylinders 4 and 6 that each have associated cams 8 and 10. The first key cylinder 4 is mounted to a lock housing 12 and the second key cylinder 6 is mounted to a lock housing cover 14. A fore-end plate 16 is also mounted to the lock housing 12.

The lock 2a includes a bolt assembly 17 comprised of a latch bolt 18, a bolt carrier with an associated bolt spring 22, a bolt carrier retaining insert 24 and an auxiliary bolt 26 with an associated auxiliary bolt spring 28. A deadlatching member, in the form of deadlatclhing rocker arm 30, is pivotally mounted to the bolt assembly 17, more particularly between the bolt carrier 20 and the bolt carrier retaining insert 24 as will be described in more detail below. The rocker arm 30 has an associated torsion spring 31.

The lock 2a also includes external handles, such as knobs or levers (not shown), which are connected to a pair of conventional square cross section drive shafts (not shown) which are in turn connected to first and second hubs 32 and 34. More particularly, each of the hubs 32, 34 has a corresponding square cross section aperture 36 for non rotationally engaging one of each of the drive shafts to transmit rotational movement from one of the handles to an associated one of the hubs 32, 34.

The lock 2c also includes a drive means, in the form of a drive rack 40 and associated drive rack spring 42, and a bolt retraction assembly, that includes a latch bolt retraction arm 44, as will also be described in more detail below.

The lock 2a also includes a pair of hub rotation locking means, in the form of first s and second hub locking sliders 46 and 48, that each have an associated engagement means, in the form of first and second locking bar engagers 49 and 50. The locking bar engagers 49, 50 can each be set in one of two positions in which an associated hub locking slider 46 and 48 respectively does, or does not, travel with movement of a locking bar 52, as will also be described in more detail below.

The lock 2a also includes a kick off actuation member, in the form of kick off lever 54, and a cylinder cam bolt retraction bar 56, the operation of which will also be described in more detail below.

The features and operation of the deadlatching assembly will now be described in more detail with reference to Figs. 5 to 17. As best seen in Fig. 5, the bolt carrier 20 and the bolt carrier retaining insert 24 are assembled by snap-engaging prongs 58 with corresponding recesses 60. Each of the carrier 20 and the insert 24 include a partial tapered cylindrical recess 62 and 64 which correspond to, and receive therein, a similarly tapered shaft 66 extending from the latch bolt 18. This allows the latch bolt 18 to be rotated about its longitudinal axis, as indicated by the doubled headed arrow 68, for easy re-handing of the lock 2a. The carrier 20 and the insert 24 also have other partial cylindrical recesses 70 and 72 which correspond to cylindrical portions 74 on the deadlatching rocker arm 30. This allows the rocker arm 30 to pivot between a deadlatching position (see Figs. 7, 10, 11, 12 and 13) and an opening position (see Figs. 6, 8, 9, 14 and 15). The rocker arm 30 is biased to the deadlatching position by the torsion spring 31. The rocker arm 30 also has first and second eccentric end protuberances 76 and 78 respectively. The protuberance 78 operatively engages with a protuberance 80 on the auxiliary bolt 26.

Figs. 12 and 13 show the latch bolt 18 in an extended position, as would occur after closure of a door. During a slam door closing action (ie. door closure without prior bolt retraction), the bolt 18 initially retracts as it travels over a strikeplate (not shown) and then extends under the influence of the spring 22 into the latch bolt opening present in a conventional strikeplate. As the stikeplate does not have an opening that corresponds to the auxiliary bolt 26, the auxiliary bolt 26 is not able to extend as far as the latch bolt 18 when the door is closed. This results in the protuberance 80 not abutting, and thus not causing pivotable movement of, the second end protuberance 78 of the rocker arm 30, as described above. The rocker arm 30 therefore pivots under the influence of the spring 31 until its other end protuberance 76 has pivotted to the position shown in Figs. 12 and 13.

As best shown in Fig. 13, when the rocker arm 30 is in this position, the first end protuberance 76 will abut a boss 82 on the cover plate 14 when the bolt 18 is attempted to be forced back into the housing 12, in the direction of arrow 84. Such movement of the bolt 18 is as would be experienced if an illegal opening of the lock 2a was attempted.

This abutment 82 stops the latch bolt 18 from being retracted and thus stops the door from being opened.

Figs. 14 and 15 show the lock 2a before door closure. As the auxiliary bolt 26 is able to extend to the same extent as the latch bolt 18, the protuberance 80 abuts, and causes pivotable movement of, the second end protuberance 78 of the rocker arm against the influence of the spring 31. This pivotable movement of the rocker arm causes its other end protuberance 76 to pivot to the position shown in Figs. 14 and 15. As best shown in Fig. 15, when the rocker arm 30 is in this position the first end protuberance 76 clears the boss 82 on the cover plate 14 as the bolt 18 is forced back into the housing 12, in the direction of arrow 84, as would be experienced during a slam door closure.

The primary advantage of the deadlatching rocker arm 30 being pivotally mounted to the bolt assembly 17 is best described with reference to Figs. 16 and 17. Fig. 16 shows the lock 2a configured for a (standard) 23 millimetre backset (backset being the distance between the outside of the cover plate and the centre line of the hubs/actuation shafts). A 23 millimetre backset is suitable for an aluminium framed door. Fig. 17 shows an almost identical lock 2b configured for use with a (standard) 60 millimetre backset, which is suitable for a standard timber door. Importantly, such a change can be simply achieved by the addition of two very simple extension pieces 86 and 88 to the bolt 18 and the auxiliary bolt 26 respectively, and the addition of a spacer block (not shown) to the housing 12. Alternatively, longer versions (not shown) of the bolt 18 and auxiliary bolt 26 can be substituted. Also, larger versions (not shown) of the housing 12 and the cover 14 can be used to obviate the need for the spacer block. All other components of the lock 2b remain unmodified. Accordingly, the lock 2a can be easily configured for many different backsets with only very minimal componentry changes, thereby obviating the need for specific lock designs for specific applications and reducing development and inventory costs.

"1 11Also advantageous is that the bolt 18 in the lock 2a is able to be retracted, for door opening, by rotation of either exterior handle in either direction, as will now be described with reference to Figs. 18 to 28. As best seen in Figs. 18 to 20, the hub 34 has a pair of protuberances, in the form of angularly spaced apart shoulders 90 and 92, and the drive rack 40 has a pair of formations, in the form of corresponding ledges 94 and 96. The drive rack 40 also has an engaging surface, in the form of gear rack 98 (see Fig. The rack 98 engages with pinion gears 100 on the latch bolt retraction arm 44 (see also Fig. 2).

The drive rack 40 is biased in the direction of arrow 102 by the spring 42, which in turn biases the hub 34 into the (first) position shown in Fig. 18.

If the exterior handle (not shown) is turned to rotate the hub anti-clockwise, as shown in Fig. 19 the first shoulder 90 engages the first ledge 94 and drives the drive rack in the direction of arrow 104 against the action of the spring 42. As the retraction arm 44 is mounted for pivotable movement only, the (downward) movement of the gear rack 98 on the drive rack 40 causes the latch bolt retraction arm 44 to pivot in an anticlockwise direction. If the exterior handle (not shown) is turned to rotate the hub 34 in a clockwise direction, as shown in Fig. 20 the second shoulder 92 engages the second ledge 96 which also drives the drive rack 40 in the direction of arrow 104 and causes counterclo~ckwise pivotable movement of the retraction arm 44, as previously described.

The retraction of the latch bolt 18 by the latch bolt retraction arm 44 will now be described with reference to Figs. 21 to 24, which correspond to the partial views shown in Figs. 25 to 28 respectively. Figs. 21 and 22 (see also Figs. 25 and 26) show the latch bolt 18 in an extended position and deadlatched. As has been previously described, the initial pivotable movement of the rocker arm 44 causes its distal end 106 to abut the first end protuberance 76 of the deadlatching rocker arm 30 and drive it from the deadlatching position to the opening position (see Figs. 23, 24, 27 and 28). As the rocker arm 30 is moved to the opening position, the distal end of the retraction arm 44 also abuts a boss 108 provided on the bolt carrier 20 and further anti-clockwise pivotable movement of the retraction arm 44 retracts the latch bolt 18 into the bolt casing 12 (see Fig. 23 and 24).

It is advantageous for bolt retraction to be achievable with handle rotation in either direction, especially when the actuation handles are knobs. Further, when this handle operation is coupled with the re-handing ability of the latch bolt described above then a single lock is provided that is suitable for use in all installations regardless of inside/outside/left hand opening/right hand opening.

The operation of the cylinder cam bolt retraction bar 56 will also be described with reference to Figs. 21 to 24. The bar 56 has a first end tab 110 which is received in a slot 112 in the drive rack 40. The other end of the bar 56 has a second end tab 114. The cam 8 of the first key cylinder 4 abuts the second end tab 114 when initially rotated in an anticlockwise direction. Further rotation of the cam 8 in the anti-clockwise direction drives the bar 56, and thus the drive rack 40, in the direction of arrow 104. The movement of the drive rack 40 is identical to that caused by rotation of the hub 34, as previously described, and causes the latch bolt retraction arm 44 to similarly retract the bolt 18 for door opening, as also previously described.

The advantages of this arrangement are two-fold. Firstly, when the cams 8 and are used (see Figs 2 and regardless if the lock is locked or unlocked a closed door can be operated single handedly (ie. if unlocked turn only key or turn only handle, if locked turn only key). However, the cams 8 and 10 can also be shortened so they cause movement of only the locking bar 52 when unlocking or locking the lock 2, thereby requiring independent movement of the cylinder cam bolt retraction bar 56 to open an unlocked or closed door. Secondly, as the key cylinder cams 8 and 10 act with common componentry to that of the handle, the overall number of components in the lock 2a is reduced thereby simplifying manufacture and assembly.

The operation of the kick off lever 54 will now be described in more detail with reference to Figs. 29 to 40. The kick off lever 54 has small and large stub shafts 116 and 118 respectively on its distal end. The shafts 116, 118 are pivotally received in corresponding recesses 120 (see Fig. 2) and 122 (see Fig. 4) provided in the lock housing 12 and lock housing cover 14 respectively. The lever 54 thus pivots about the shafts 116, 118 with respect to the lock housing 12 and the cover 14. The bolt carrier retaining insert 24 has a drive boss 124 adjacent the lever 54 which itself has a drive boss 126. The lever 54 also has a detent 128, which travels within a slot 130 (see Fig. 4) in the lock housing cover 14, that is biased to either end of the slot 130. The middle of the lever 54 has a raised portion with a slot 132 therein. When assembled, the slot 132 is accessible through an opening 134 (see Fig. 2) in the lock housing cover 14. A screw driver or like tool can be inserted through the opening 134 into the slot 132 and used to position the kick off lever 54 in a (inactive) position in which the detent 128 is held in the top of the slot 130 or a (active) position in which the detent 54 is held lower in the slot 130 (see Figs. 37 to The distal end of the lever 54 also includes a shoulder 136 which protrudes into a recess 138 in the locking bar 52. The recess 138 has a lower tab 139. The locking bar 52 -11- 'can be linked for movement with the first and second hub locking sliders 46 and 50 for locking and unlocking the lock 2, as will be described in more detail below. For present L purposes it is sufficient to say that driving the locking bar 52 in the direction of arrow 140 can unlock the lock 2.

Figs. 29, 30, 33 and 34 show the kick off lever 54 in the inactive position. During 'A closure of a door, the bolt 18 rides over the strikeplate and is moved from an extended 3 position (Figs. 29 and 33) to a retracted position (see Figs. 30 and 34). During this 'A movement the drive boss 124 on the bolt carrier retaining insert 24 slides beneath the O drive boss 126 on the lever 54 without any driving contact being made therebetween.

l 1 i0 Accordingly, this movement does not affect the position of the kick off lever 54 or the locking bar 52 and, when the kick off lever 54 is in the inactive position, closure of the door will not unlock the door. When the kick off lever 54 is in the active position (Figs.

31, 32, 35 and 36) then closing of the door as previously described causes the drive boss 124 to abut the lever drive boss 126 and pivot the lever 54 such that the shoulder 136 pivots in the direction of the arrow 140. This causes the shoulder 136 to engage the recess tab 139 and drive the locking bar 52 in the direction of arrow 140, thereby altering the lock 2a from locked to unlocked.

Placing the kick off lever 54 in the active position therefore provides a safe guard against inadvertent locking of the door upon closure. An advantage provided by the kick off lever 54 is that it operates in conjunction with a component of the lock used for other purposes (ie. the locking bar) thereby reducing the number of components and the production and assembly cost of the lock overall.

A more detailed explanation of the operation of the locking bar 52 will now be given with reference to Figs. 41 to 48. As best seen in Figs. 41 and 42, the locking bar 52 has a pair of upper recesses 142. Each of the first and second hub locking sliders 46, 48 have a slotted recess 143 which receives one of the locking bar engagers 49, 50 therein.

The engagers 49, 50 have a slot 144 which is accessible through an opening 146 in the lock housing 12 and cover 14 respectively. A screw driver or like tool can be inserted into the openings 146 to set the engagers 49, 50 in an engaged position in which an end of the engagers 49, 50 is received within one of the slots 142 (see Figs. 43 and 44) or a disengaged position in which the engagers 49, 50 do not enter the recess 142 (see Figs. and 46). The engager's 49, 50 are held in either of the engaged or disengaged positions by their other end engaging one of two detent slots 148 (see Figs. 44 and 46) in the hub locking sliders 46, 48. The other end of the locking bar 52 has an angled tab 148.

The engagers 49,50 each also have a protuberance 49a,50a respectively, which are ,.each received in a L-shaped recess 149 in each of the locking housing 12 and lock housing cover 14, as will be explained in more detail below.

When the (short version) cylinder cam 8 is driven in the counter-clockwise direction past the position shown in Fig. 23, it initially abuts the angled tab 148. Further anticlockwise movement forces the locking bar 52 in the direction of arrow 150. If either of the locking bar engagers 49 and 50 are set in the engaged position (see Figs. 43, 44 and 47) then such movement of the locking bar 52 will cause corresponding movement in the 8 associated hub locking sliders 46, 48. During this movement, the engager's 10 protuberances 49a, 50a travel within the longer arm of one of the L-shaped recesses 149.

Each of the sliders 46, 48 also have a recess 152 which corresponds to the protuberance 154 on each of the hubs 32, 34 (see Figs. 2 and Accordingly, driving the locking bar 52 and any engaged hub locking sliders 46, 48 also drives the associated recess 152 over the protuberance 154 which prevents rotation of the hub 32, 34 and locking of the door. It is important to note that the engagers 49, 50 are independently settable so as to allow the lock operator to set from which side or both the door may be locked. It is also important to note that the hubs 32,34 operate in both turning directions and that the engagement of the recesses 152 and the protuberances 154 also locks the hubs 32,34 against rotation in both directions.

When either of the engagers 49, 50 is set to the disengaged position (see Figs. 46 and 48) then the key movement previously described will cause movement of the locking bar 52 in the direction 150 relative to the stationary hub locking slider 46 or 48.

Accordingly, the recess 152 shall remain free of the protuberance 154 and allow movement of the associated hub 32, 34 and unlocking of the door from that side. In this position, the engager's protuberances 49a,50a each remain in the shorter arm of one of the L-shaped recesses 149.

The main advantage of this engager arrangement is that the engagers travel only as much as the locking bar and thus, in either position, do not add to the overall length of the locking bar and its associated components, as with known mortice locks. This reduces the space needed for the lock componentry and allows production of a smaller lock.

Further, when the engagers 49,50 are set in the disengaged position, no movement is caused in the sliders 46,48 thereby reducing the number of moving parts in the lock 2a and associated friction.

Figs 49 to 92 show a second embodiment of a mortice lock 2c which includes examples of the five aspects of the invention. The lock 2c functions similar to the lock 2a and like reference numerals to those used in describing the lock 2a shall be used to indicate like or similar features with respect to the lock 2c.

Turning firstly to Figs 49 to 53 the lock 2c includes first and second key cylinders 4 and 6 that each have associated cams 8 and 10. The first key cylinder 4 is mounted to a lock housing 12 by a pin 13 and a second key cylinder 6 is mounted to a lock housing cover 14 by a pin 15. A fore-end plate 16 is also mounted to the lock housing 12.

The lock 2c includes a bolt assembly 17 (see Figs. 53 to 55) comprised of a latch bolt 18, a bolt carrier 20 with an associated bolt spring 22. The lock 2c also includes an auxiliary bolt assembly 226, with an auxiliary bolt 26 and an auxiliary bolt carrier 27, the latter being associated with an auxiliary bolt spring 28. A deadlocking member, in the form of deadlatching pivot arm 30, is pivotally mounted to the bolt assembly 17, more particularly to the bolt carrier 20 as will be described in more detail below. The pivot arm 30 has an associated torsion spring 31.

The lock 2c also includes external handles such as knobs or levers (not shown) which are connected to a pair of conventional square cross-section drive shafts (not shown) which are in turn connected to first and second hubs 32 and 34. More particularly, each of the hubs 32, 34 has a corresponding square cross-section aperture 36 for non-rotationally engaging each one of the drive shafts to transmit rotational movement from one of the handles to an associated one of the hubs 32, 34.

The lock 2c also includes a drive means and a bolt retraction assembly, that are incorporated into a latch bolt retraction member 44 as will also be described in more detail below.

The lock 2c also includes a pair of hub rotation locking means, in the form of first and second hub locking sliders 46 and 48, that each have an associated engagement means, in the form of first and second locking bar engagers 49 and 50. The locking bar engagers 49, 50 can each be set in one of two positions in which an associated hub locking slider 46 and 48 respectively does, or does not, travel with movement of a locking bar 52, as will also be described in more detail below.

The lock 2c also includes a kick-off actuation member, in the form of kick-off block 54, a cam pivot link 254 and a cylinder cam bolt retraction bar 56, the operation of which will also be described in more detail below.

The features and operation of the deadlatching assembly will now be described in more detail with reference to Figs. 53 to 63. As best seen in Fig. 53, the bolt carrier includes a cylindrical recess 62 which corresponds to, and receives therein, a similar shaft 66 extending from the latch bolt 18. The latch bolt 18 is retained adjacent the carrier by a circlip 266. The auxiliary latch bolt 26 is retained adjacent the auxiliary bolt carrier 27 by a circlip 366. This allows the latch bolt 18 and the auxiliary latch bolt 26 to be rotated about their longitudinal axes, as indicated by the double headed arrow 68, for easy re-handing of the lock 2c. The carrier 20 has another cylindrical recess 72 which corresponds to cylindrical portion 74 (see Fig. 52) on the dead latching pivot arm This allows the pivot arm 30 to pivot between a deadlatching position (see Fig. 54, 55, 57, 58 and 59) and an opening position (see Figs. 54, 60 and 61). The pivot arm 30 is biased to the deadlatching position by the torsion spring 31. The pivot arm 30 also has first, second and third protuberances 76, 78 and 79 respectively. The protuberance 78 operatively engages with a protuberance 80 on the auxiliary bolt carrier 27.

Figs. 58 and 59 show the latch bolt 18 in an extended position, as would occur after closure of a door. During a slam door closing action, the bolt 18 initially retracts as it travels over a strikeplate (not shown) and then it extends under the influence of the spring 22 into the latch bolt opening present in a conventional strikeplate. As the strikeplate does not have an opening that corresponds to the auxiliary bolt 26, the auxiliary bolt 26 is not able to extend as far as a latch bolt 18 when the door is closed.

This results in the protuberance 80 abutting, and causing pivotal movement of, the second protuberance 78 of the pivot arm 30, as described above. This pivotal movement of the pivot arm 30 causes the first protuberance 76 to pivot to the position shown in Fig.

58 and 59. As best shown in Fig. 59, when the pivot arm 30 is in this position the first protuberance 76 abuts a boss 82 on the cover plate 14 when the bolt is attempted to be forced back into the housing 12, in the direction of arrow 84. Such movement of the bolt 18 is as would be experienced if an illegal opening of the lock 2c was attempted. The boss 82 stops the latch bolt 18 from being retracted and thus stops the door from being opened.

Figs. 60 and 61 show the lock 2c before door closure. As the auxiliary bolt 26 is able to extend to the same extent as the latch bolt 18, the protuberance 80 abuts, and causes pivotable movement of, the second protuberance 78 of the rocker arm 30 against the influence of the spring 31. This pivotable movement of the rocker arm 30 causes the first protuberance 76 to pivot to the position shown in Figs. 60 and 61. As best shown in Fig. 61, when the rocker arm 30 is in this position the first end protuberance 76 clears the boss 82 on the cover plate 14 as the bolt 18 is forced back into the housing 12, in the direction of arrow 84. Such movement of the bolt 18 is as would be experienced during a slam door closure.

The primary advantage of the deadlatching pivot arm 30 being pivotally mounted to the bolt assembly 17 is best described with reference to Figs. 62 and 63. Fig. 62 shows the lock 2c configured for a (standard) 23 mm backset. A 23 mm backset is suitable for an aluminium frame door. Fig. 63 shows an almost identical lock 2d configured for use with a (standard) 60 mm backset which is suitable for a standard timber door.

Importantly, such a change can be simply achieved by the addition of two very simple extension pieces 86 and 88 to the bolt 18 and the auxiliary bolt 26 respectively," and the use of an extended housing 12a. Alternatively, longer versions (not shown) of the bolt 18 and auxiliary bolt 26 can be substituted. All other components of the lock 2c remain unmodified. Accordingly, the lock 2c can be easily configured for many different backsets with only very minimal componentry changes, thereby obviating the need for specific lock designs for specific applications and reducing development and inventory costs.

Also advantageous is that the bolt 18 in the lock 2c is able to be retracted, for door opening, by rotation of either exterior handle in either direction, as will now be described with reference to Figs. 64 to 70. As best seen in Figs. 64 to 66, the hub 34 has a pair of angularly spaced apart protuberances 90 and 92 and the latch bolt retraction member 44 has a pair of corresponding formations 94 and 96. The latch bolt retraction member 44 is biased in the direction of arrow 202 by the spring 42, which in turn biases the hub 34 into the (first position) shown in Fig. 64.

If the exterior handle (not shown) is turned to rotate the hub anticlockwise, as shown in Fig. 66, the first protuberance 90 engages the first formation 94 and pivots the latch bolt retraction member 44 in the opposite direction of arrow 202 and against the action of the spring 42 as the retraction arm 44. If the exterior handle (not shown) is turned to rotate the hub 34 in a clockwise direction, as shown in Fig. 65, the second protuberance 92 engages the second formation 96 which also causes counter clockwise pivotal movement of the retraction arm 44, as previously described.

The retraction of latch bolt 18 by the latch bolt retraction arm 44 will now be described with reference to Figs. 67 to 70. Figs. 67 and 68 show the latch bolt 18 in an extended and deadlatched position. As has been previously described, the initial pivotal -16movement of the rocker arm 44 causes its distal end 106 to abut the third protuberance 79 of the deadlatching pivot arm 30 and drive the pivot ann 30 from the deadlatching position to an opening position. As the pivot arm 30 is moved to the opening position, the distal end of the retraction arm 44 also abuts a boss 108 provided on the bolt carrier and ftrther anticlockwise pivotal movement (see Figs. 69 and 70) of the retraction arm 44 retracts the latch bolt 18 into the bolt casing 12.

It is advantageous for bolt retraction to be achievable with handle rotation in either direction, especially when the actuation handles are knobs. Further, when this handle operation is coupled with the re-handing ability of the latch bolt described above then a single lock is provided that is suitable for use in all installations regardless of inside/outside/left hand opening/right hand opening.

The operation of the retraction bar 56 will now be described with reference to Figs.

71 to 73, which show the lock 2c with a "short" version of the cam 8 that has external gears 208. The bar 56 has a first end tab 110 which engages a camming member 210 which is pivotally mounted to the lock cover 14. The other end of the bar 56 has an opening 212 which engages with a spigot 214 provided on the retraction member 44.

When a key is inserted to the cylinder 4 and rotated, corresponding rotation is caused in the cam 8 which causes it to initially engage the cam member 210 (see Fig. 72).

Continued rotation of the cam 8 causes the cam member 210 to rotate to the position shown in Fig. 73 which causes corresponding downward movement in the retraction bar 56. This movement of the retraction bar 56 causes the retraction member 44 to pivot in an anticlockwise direction such that the distal end 106 of the retraction arm 44 abuts the boss 108 provided on the bolt carrier 20 and retracts the latch bolt 18 into the bolt casing 12, in the manner previously described. The movement of the cam 8 does not influence the position of the cam pivot link 254. Accordingly, the short cam is only able to retract the latch bolt. It cannot lock or unlock the locking bar.

The advantages of the short cam arrangement is the key cylinder cams 8 and have a common component to that of the handle the overall number of components in the lock 2c is reduced thereby simplifying manufacture and assembly.

The operation of the locking bar 52 and the retraction bar 56 will now be described with reference to Figs. 74 to 77, which show the lock 2c with a "medium" version of the cam 8 that has external gears 208 and a medium length finger 308. Fig. 74 shows the finger 308 rotated to a position that pivots the cam pivot link 254 anti-clockwise. This causes upward movement in the locking bar 52 that results in the lock 2c being locked, as will be described below. Fig. 75 shows the finger 308 rotated to a position that pivots the cam pivot link 254 clockwise. This causes downward movement in the locking bar 52 that results in the lock 2c being unlocked, as will be described below. Fig. 76 shows the finger 308 further rotated to a position that pivots the cam 8 such that the gears 208 initially engage the cam member 210. Continued rotation of the cam 8 causes the cam member 210 to rotate to the position shown in Fig. 77 which causes corresponding downward movement in the retraction bar 56. This movement of the retraction bar 56 causes the retraction member 44 to pivot in an anticlockwise direction such that the distal end 106 of the retraction arm 44 abuts the boss 108 provided on the bolt carrier 20 and retracts the latch bolt 18 into the bolt casing 12, in the manner previously described.

The advantages of the medium cam arrangement are two-fold. Firstly, regardless if the lock is locked or unlocked a closed door can be operated single handedly (ie. if unlocked turn only key or turn only handle, if locked turn only key). Secondly, as the key cylinder cams 8 and 10 have a common component to that of the handle the overall number of components in the lock 2c is reduced thereby simplifying manufacture and assembly.

The operation of the locking bar 52 will now be described with reference to Figs. 78 to 80, which show the lock 2c with a "long" version of the cam 8 that has long length finger 408. Fig. 78 shows the finger 408 in a neutral position where it does not engage the cam pivot link 254. Fig. 79 shows the finger 408 rotated to a position that pivots the cam pivot link 254 clockwise. This causes downward movement in the locking bar 52 that results in the lock 2c being unlocked, as will be described below. Fig. 80 shows the finger 408 rotated to a position that pivots the cam pivot link 254 anti-clockwise. This causes upward movement in the locking bar 52 that results in the lock 2c being locked, as will be described below. Accordingly, the long cam 8 is only able to lock or unlock the locking bar. It cannot retract the latch bolt.

The advantages of the long cam arrangement is, as the key cylinder cams 8 and have a common component to that of the handle, the overall number of components in the lock 2c is reduced thereby simplifying manufacture and assembly.

By configuring each side of the lock 2e with appropriate short, medium or long cams, the lock 2c can be customised for different applications and access requirements.

The operation of the kick-offblock 54 will now be described in more detail with reference to Figs. 81 to 84. The block 54 pivots about shaft 74, which is received within a corresponding recess in the bolt carrier 20. The block 54 has a detent 228 which engages -18one of two corresponding'detents 230. in the bolt carrier 20. The block also includes a slot 232 which, after assembly, is accessible through an opening 234 (see Figs. 82 and 84) in the lock cover housing 14. A screwdriver or like took can be inserted through the opening 234 into the slot 232 and used to position the kick-off block 54 in an inactive position (as shown in Figs. 81 and 82) or an active position (as shown in Figs. 83 and 84).

The cam pivot link 254 has three portions 254a, 254b and 254c. The portion 254c is positioned towards the kick-off block 54 and is also engaged with the locking bar 52. The locking bar 52 can be linked for movement with the first and second hub-locking sliders 46 and 50 for locking and unlocking the lock 2c, as will be described in more detail below. For present purposes is sufficient to say that driving the locking bar 52 in the direction of arrow 140 can unlock the lock 2c.

Figs. 81 and 82 show the kick-off block 54 in the inactiveposition During closure of the door, the bolt 18 rides over the strikeplate and is moved from an extended position to a retracted position. During this movement the kick-off block 54 slides over the cam pivot link portion 254c without any driving contact being made therebetween.

Accordingly, this movement does not affect the position of the kick-off block 54 or the cam pivot link 254 or the locking bar 52. Therefore, when the kick-off lever 54 is in the inactive position, closure of the door will not unlock the lock 2c.

When the kick-off block 54 is in the active position (see Figs. 83 to 84) then closing of the door as previously described causes the drive block to contact the cam pivot link portion 254c. Further retraction of the bolt 18 results in the cam pivot link 254 being pivoted in an anticlockwise direction to position shown in Fig. 86. This causes the locking bar 52 to be driven in the direction of arrow 140, thereby altering the lock 2c from locked to unlocked.

Placing the kick off block 54 in the active position therefore provides a safe guard against inadvertent locking of the door upon closure. An advantage provided by the kick off block 54 is that it operates in conjunction with components of the lock used for other purposes (ie. the locking bar and the cam pivot link) thereby reducing the number of components and the production and assembly cost of the lock overall.

A more detailed explanation of the operation of the locking bar 52 will now be given with reference to Figs. 87 to 92. As best seen in Figs. 87 and 88, the locking bar 52 has a pair of upper recesses 142. Each of the first and second hub locking sliders 46, 48 have a slotted recess 143 which receives one of the locking bar engagers 49, 50 therein.

The engagers 49, 50 have a tab 144 which is accessible through an opening 146 in the -19lock housing 12 and cover 14 respectively. A screw driver or like tool can be inserted into the openings 146 and push the tab 144 to set the engagers 49, 50 in an engaged position in which an end of the engagers 49, 50 is received within one of the slots 142 (see Figs. 89 and 90) or a disengaged position in which the engagers 49, 50 do not enter the recess 142 (see Figs. 91 and 92). The engagers 49, 50 are held in either of the engaged or disengaged positions by legs 49b and 50b engaging one of two detent slots 148 (see Figs. 90 and 92) in the hub locking sliders 46, 48. The other end of the locking bar 52 has an angled tab 148, which engages a complimentary slot in the cam pivot link 254.

The engagers 49,50 each also have a protuberance 49a,50a respectively, which are each received in a L-shaped recess 149 in each of the locking housing 12 and lock housing cover 14, as will be explained in more detail below.

When the pivot cam link 254 is driven anti-clockwise, as described above, the locking bar 52 (which is connected thereto) is forced in the direction of arrow 150. If either of the locking bar engagers 49 and 50 are set in the engaged position (see Figs. 89 and 90) then such movement of the locking bar 52 will cause corresponding movement in the associated hub locking sliders 46, 48. During this movement, the engager's protuberances 49a, 50a travel within the longer arm of one of the L-shaped recesses 149.

Each of the sliders 46, 48 also have a recess 152 which corresponds to the protuberance 154 on each of the hubs 32, 34 (see Figs. 50 and 52). Accordingly, driving the locking bar 52 and any engaged hub locking sliders 46, 48 also drives the associated recess 152 over the protuberance 154 which prevents rotation of the hub 32, 34 and locking of the door. It is important to note that the engagers 49, 50 are independently settable so as to allow the lock operator to set from which side or both the door may be locked. It is also important to note that the hubs 32,34 operate in both turning directions and that the engagement of the recesses 152 and the protuberances 154 also locks the hubs 32,34 against rotation in both directions.

When either of the engagers 49, 50 is set to the disengaged position (see Figs. 91 and 92) then the movements previously described will cause movement of the locking bar 52 in the direction 150 relative to the stationary hub locking slider 46,48. Accordingly, the recess 152 shall remain free of the protuberance 154 and allow movement of the associated hub 32, 34 and unlocking of the door from that side. In this position, the engager's protuberances 49a,50a each remain in the shorter arm of one of the L-shaped recesses 149.

The main advantage of this engager arrangement is that the engagers travel only as much as the locking bar and thus, in either position, do not add to the overall length of the locking bar and its associated components, as with known mortice locks. This reduces the space needed for the lock componentry and allows production of a smaller lock.

s Further, when the engagers 49,50 are set in the disengaged position, no movemeit is caused in the sliders 46,48 thereby reducing the number of moving parts in the lock 2c and associated friction.

The embodiments of the locks described above possess many specific advantages arising from the numerous inventive aspects of particular componentry. However, the locks are also generally advantageous over those of the prior art due to their reduced componentry and simplicity.

Although the invention has been described with reference to a specific examples, it will be appreciated with those skilled in the art that the invention may be embodied in many other forms. Further, many components have only been described with reference to one side of the locks and the skilled person will also appreciate that the same components on the other side of the locks operate in a similar manner.

Claims (8)

1. A mortice lock comprising: a lock housing; a drive shaft adapted to be rotationally driven about an axis by a handle or knob; a hub mounted on the shaft for rotation therewith from a first position towards either a second clockwise position and a third anti-clockwise position, the hub having a pair of spaced apart protuberances; and a drive means adapted for movement relative to the housing, the drive means having a pair of formations and an engaging surface adapted, upon moving, to cause movement in a bolt retraction assembly, wherein clockwise movement of the hub to the second position causes one of the protuberances to abut one of the formations and cause the drive means to move in a first direction and anti-clockwise movement of the hub to the third position causes the other of the protuberances to abut the other of the formations and also cause the drive means to Is move in the first direction.

2. The lock as claimed in claim 1, wherein the drive means is mounted for slidable movement relative to the housing.

3. The lock as claimed in claim 1, wherein the drive means is mounted for pivotal movement relative to the housing and incorporates the bolt retraction assembly therein.

4. The lock as claimed in claim 1, 2 or 3, wherein the bolt retraction assembly is moved to retract the bolt regardless of which direction (clockwise or anti- clockwise) the handle or knob is rotated.

The lock as claimed in any one of the preceding claims, wherein the drive means is spring biased in a second direction opposite the first direction and also biases the hub to the first position.

6. The lock as claimed in any one of the preceding claims, wherein the lock includes a pair of the drive shafts and a pair of the hubs, each mounted on one of the drive shafts, and the drive means contains two pairs of formations, wherein each one of the pairs of formations is adapted to engage each one of the pairs of protuberances when the hubs are in the first position.

681204-1:KEH

7. The lock as claimed in any one of the preceding claims, wherein the bolt retraction assembly includes a pivotable latch arm and the drive member engaging surface is a gear rack adapted to engage with a gear portion provided on the latch arm.

8. The lock as claimed in any one of the preceding claims, wherein the bolt retraction assembly is an arm pivotally mounted to the lock housing. Dated 16 February, 2007 Gainsborough Hardware Industries Limited Patent Attorneys for the Applicant/Nominated Person SPRUSON FERGUSON 681204-1:KEH