US3256918A - Method for preparing a door for installation of a unit lock - Google Patents

Description

June 21, 1966 F. J. RUSSELL ETAL 3,256,918

METHOD FOR PREPARING A DOOR FOR INSTALLATION OF A UNIT LOCK Filed Oct. 28, 1963 w W 1 l6 l5 1!" hlilhlii lO '20 1/ 2o y -|I 7 MI IL '[ii Mimi-CH2 4| IO f\ 22 \Y 40 5 -4-- IO INVENTORS F250 J- RUSSELL ROGER J2 Now/4 AT ORN 5Y5 Patented June 21, 1966 3,256,918 NIETHOD FOR PREPARING A DOOR FOR INSTALLATION OF A UNIT LOCK Fred J. Russell, 8635 Otis St., South Gate, Calif., and

Roger J. Nolin, Monterey Park, Calif.; said Nolin assignor to said Russell Filed Oct. 28, 1963, Ser. No. 319,117 3 Claims. (Cl. 144-326) The invention relates to installation techniques in preparing a door for installation of a lock of a particular kind. The lock involved in one which customarily is inserted inwardly of the edge of the door, requiring a relatively large cut-out to accommodate the lock casing or housing.

There is a certain line of locks of a relatively rugged type, with great security potential, which requires a technique for installation slightly different from the technique and practices employed in the location of ordinary resi-- dential locks. The lock under consideration, although known by various names, consists of a housing substantially as thick as the door thickness itself and having a length, at and adjoining the door edge area, which extends a relatively substantial distance from the adjacent edge of the door. Heretofore, the hole made in the door for reception of a lock of the type under consideration was made by sawing two parallel saw cuts from the edge of the door and then chiseling out at the inner end between the ends of the two saw cuts in order to accommodate the inner end of the lock housing. Chiseling, however, is a time-consuming process. Further still, chiseling is rather wasteful of wood and cannot be done with any great degree of neatness. Further still, when a combination of saw cuts and chiseling is resorted to, more wood is broken away than necessary, and this detracts to an unnecessary degree from the strength of the door. Although some doors of conventional construction may lend themselves to a chiseling process, doors with a fine veneer finish are often damaged at the surface in such a chiseling process, even though the craftsman exercises considerable care in order not to splinter the surface veneer.

It is among the objects of the invention to provide a new and improved method for preparing a door for the installation of that type of lock which is inserted into a notch cut-out in the edge of the door which is positive, rapid, and also one which assures a neat installation without unnecessarily sacrificing the strength of the door.

Another object of the invention is to provide a new and improved method for installing that type of lock which installs into a notch cut-out in the edge face of the door which may be limited to three rapid direct operations, namely, the boring of a hole and the making of two cuts from the edge'of the door to the edge of the hole, thereby to prepare the door for installation of the lock.

Another object of the invention is to provide a new and improved method for preparing a door for installation of that type of lock which installs into a notch cutout in the edge faces of the door which reduces the time required to cut the back end of the notch, which makes possible a much more rapid installation of the lock in the door, and also one which gives great assurance of a neat door cut-out.

With these and other objects in view, the invention consists in the arrangement and combination of the various aspects of the method, whereby the objects contemplated are attained, as hereinafter set forth and pointed out in the appended claims and illustrated in the accompanying drawings.

In the drawings:

FIGURE 1 shows a'fragmentary side elevational view of a door with the initial operation completed.

FIGURE 2 is an exploded view showing in part a:

fragmentary side elevation of the door with the door completed for installation of'a lock housing, and such a lock housing in a position ready for insertion.

FIGURE 3 is a fragmentary side elevational view of a door with the lock housing in place.

FIGURE 4 is a cross-sectional view taken on the line 44 of FIGURE 2.

FIGURE 5 is a fragmentary side elevational view of the door with a notch cut-out slightly different from the cutout of FIGURE 2.

FIGURE 6 is a fragmentary side elevational view of a door similar to FIGURE 5 but showing a third manner of making an appropriate cutout.

In an embodiment of the invention chosen for the purpose of illustration, there is shown a door 10 having a free or swinging edge 11 and possessed of opposite faces 12 and 13. The method here under consideration is one adapted to prepare the door 10 for installation of a lock housing like the lock housing indicated generally by the reference character 15. In the form of lock housing illustrated, the housing consists of parallel upper and lower edges 16 and 17, respectively, extending inwardly to an area of substantial tangency to a rounded inside end 18. Ordinarily, in order to take greatest advantage of the method here involved, the inside end is semi-circular I and made to a radius equal to substantially half the distance between the parallel upper and lower edges 16 and 17. Although not expressly illustrated in the drawing, the thickness of the housing 15 is substantially the some slight variation from the expressed exemplary dimensions may be encountered while falling within the invention herein disclosed. The knob, spindles, and escutcheon plates of the lock are conventional and are not shown. Generally, the escutcheon plates clamp the faces 12 and 13.0f the door 10 and overlap all areas of the door cut-out to the left of a ridge 19 of the lock as identified in FIGURE 2. i

To make the desired cut-out, a hole 20 is located at a distance inwardly from the edge 11 such that the hole will provide a free fit for the rounded inside end 18 of the lock when the lock housing is in proper position in the door. Although the clearance need not be great, it is best to have a clearance which will offer no impediment to the full insertion of the lock housing when it is fitted into position from the edge of the door. I

After the hole 20 is neatly bored through the door, preferably in part inward from the face 12 and in part inward from the face. 13 to avoid splintering, cuts are made inwardly from the edge 11. An upper cut resulting in an upper inside edge 21 is spaced from a lower cut ultimately forming a lower inside edge 22 by a distance substantially equal to the distance between the upper and lower edges 16 and 17 of the lock, or very slightly greater. These cuts are then extended inwardly until they join respectively upper and lower edges of the hole 20. Where the hole 20 is slightly greater in diameter than the distance between the inside edges 21 and 22, the saw cuts will entirely loosen the portion of door-material there- 1 between, which then can be readily removed without effort. In this instance also, inasmuch as the diameter of and 17 respectively with the upper inside edge 21 and the lower inside edge 22 will be depended upon to snugly and accurately position the lock housing in the notch thus formed.

Further still, by reason of carefully locating the hole at a proper distance inwardly from the edge 11, an end face 23 of the lock housing 15 can be brought precisely flush with the end edge 11 of the door, while still permitting a space 24 remaining between the inside end 18 of the lock and the innermost surface of the hole 20.

In the form of invention in FIGURE 5, slightly greater accuracy is required in the operation in that the diameter of a hole is made substantially the same as the distance between an upper inside edge 31 and a lower inside edge 32. In this example, the saw cuts, which accomplish respectively the forming of the upper and lower inside edges 31 and 32, are spaced apart a distance substantially equal to the diameter of the hole 30 and are aligned precisely with the upper edge 33 and the lower edge 34. This usually means a snugger fit therein of the lock housing 15, but by spacing a center 36 of the hole 30 inwardly far enough, a clearance still will be provided between most of an arcuate portion of the hole 30 and the inside rounded end 18 of the lock housing 15.

In still another form of the invention illustrated in FIGURE 6, it may be assumed that an inside rounded end similar to the end 18 of the lock housing 15 has a slightly different configuration or that the spacing between parallel upper and lower edges 16 and 17 is slightly greater. In this instance, a hole 40 is bored with its center 41 spaced a desired distance inwardly from the edge 11 of the door 10. Here again, the spacing of parallel upper and lower saw cuts resulting in the production of a parallel upper edge 42 and a parallel lower edge 43 should be such as to provide a substantially snug fit between corresponding upper and lower parallel edges of the appropriate lock housing. When the saw cuts from the edge 11 are made for this form of device, they will never precisely cut through into the hole 40. The cuts, however, may be extended to points 44 and 45 through a location almost or substantially opposite the upper and lower extremities of the hole 40. By bringing the cuts inward to this point, wood material of the door 10 will be weakened suificiently so that the wood material can be knocked loose, breaking the small remaining thicknesses of material between the points 44 and 45 and the wall of the hole 40. Since lock housings of the kind under corisideration invariably employ escutcheons to overlap the faces of the door, the presence of broken material at the points 44 and 45 will not be detrimental to the appearance of the installation after it has been completed, for they will be covered up by the escutcheons.

It will be appreciated that the installation method can be accomplished with substantially a minimum number of operations, namely, a simple transverse boring operation'followed by two saw cuts which can easily be located at the swinging edge 11 of the door.

While the invention has herein been shown and described in what is conceived to be the most practical and preferred embodiment, it is recognized that departures may be made therefrom within the scope of the invention, which is not to be limited to the details disclosed herein but is to be accorded the full scope of the claims so as to embrace any and all equivalent methods.

Having described the invention, what is claimed as new in support of Letters Patent is:

1. A method of preparing a door at an edge for the installation of a lock of the type which installs in acutout notch at said edge, said method comprising locating a hole of selected radius at least as large as the inside end of said lock, boring said hole through the door from one face to the other, making two plane face cuts through said door inwardly from said edge with the plane faces of the cuts parallel to each other throughout the length thereof and spaced from each other a distance equal to the diameter of said hole and approximately the same as the distance between said parallel upper and lower edges of the lock, whereby to provide a snug fit for the upper and lower edges of said lock, continuing making said cuts until both said cuts substantially meet respectively upper and lower edges of said hole and form lines of junction with said hole parallel to said plane faces and to each other, and then removing door material defined by said hole and said cuts.

2. A method of preparing a door at an edge for the installation of a lock of the type which installs in a cutout notch at said one edge wherein the lock has an inside rounded end and substantially parallel upper and lower edges, said method comprising locating a hole slightly larger than said rounded end and having a diameter between one half and twice the thickness of the door, boring said hole through the door from one face to the other whereby to provide a free fit for said rounded end, making two plane face cuts parallel to each other through said door inwardly from said edge with the cuts spaced from each other a distance equal to the diameter of said hole and substantially the same as the distance between said parallel upper and lower edges of the lock at its door edge end, whereby to provide a snug fit for said upper and lower edges, continuing making said cuts until both said cuts substantially meet respectively upper and lower edges of said hole, and then removing door material released by said cuts.

3. A method of preparing a door at an edge thereof for the installation of a lock of the type which installs in a cut-out notch at said edge wherein the lock has an inside end which will fit within a selected radius and has substantially parallel upper and lower edges at its door edge end, said method comprising locating a hole of said selected radius at a distance inwardly from said edge, boring said hole through the door from one face to the other whereby to provide a free fit for said inside end, making a first cut through said door progressively inwardly from said edge and then making a second cut through said door progressively inwardly from said edge and parallel to the first cut, said cuts being spaced from each other a distance only slightly greater than the diameter of said hole and approximately the distance between said parallel upper and lower edges of the lock, whereby to provide a snug fit for said upper and lower edges, continuing making said cuts'until both said cuts substantially meet respectively upper and lower edges of said hole, and then removing door material released by said cuts.

References Cited by the Examiner UNITED STATES PATENTS 1,080,073 12/ 1913 Morehouse 14435 2,356,046 8/1944 Garlick 93l 2,790,470 4/ 1957 Graham 14427 2,814,219 11/1957 Zern 144-27 HAROLD D. WHITEHEAD, Primary Examiner.

WILLIAM W. DYER, ]R., Examiner.

Claims (1)

1. A METHOD OF PREPARING A DOOR AT AN EDGE FOR THE INSTALLATION OF A LOCK OF THE TYPE WHICH INSTALLS IN A CUTOUT NOTCH AT SAID EDGE, SAID METHOD COMPRISING LOCATING A HOLE OF SELECTED RADIUS AT LEAST AS LARGE AS THE INSIDE END OF SAID LOCK, BORING SAID HOLE THROUGH THE DOOR FROM ONE FACE TO THE OTHER, MAKING TWO PLANE FACE CUTS THROUGH SAID DOOR INWARDLY FROM SAID EDGE WITH THE PLANE FACES OF THYE CUTS PARALLEL TO EACH OTHER THROUGHOUT THE LENGTH THEREOF AND SPACED FROM EACH OTHER A DISTANCE EQUAL TO THE DIAMETER OF SAID HOLE AND APPROXIMATELY THE SAME AS THE DISTANCE BETWEEN SAID PARALLEL UPPER AND LOWER EDGES OF THE LOCK, WHEREBY TO PROVIDE A SNUG FIT FOR THE UPPER AND LOWER EDGES OF SAID LOCK, CONTINUING MAKING SAID

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