WO2018217477A1

WO2018217477A1 - Low-profile deadbolt assembly and deadbolt actuation mechanism

Info

Publication number: WO2018217477A1
Application number: PCT/US2018/032254
Authority: WO
Inventors: Dean Grant BEARDMORE; Bryan Hugh MARSHALL
Original assignee: Illinois Tool Works Inc.
Priority date: 2017-05-26
Filing date: 2018-05-11
Publication date: 2018-11-29

Abstract

A double-cylinder deadbolt door lock assembly comprising a deadbolt mechanism with a bolt arranged for sliding movement along a bolt axis between retracted and extended configurations, and first and second actuators provided for operating the deadbolt mechanism, in use, from respective sides of the door, the first and second actuators comprising respective key operated lock cylinders, wherein the axes of rotation of the lock cylinders are transverse to the bolt axis, and offset from one another so as to be disposed to opposite sides of the bolt axis.

Description

LOW-PROFILE DEADBOLT ASSEMBLY AND DEADBOLT ACTUATION

MECHANISM

PRIORITY

This application claims priority to and the benefit of Australian Application

No. 2017902002, filed May 26, 2017 and Australian Application No. 2018203174, filed May 8, 2018 the entire contents of each of which are incorporated herein by reference. FIELD OF THE INVENTION

The present invention relates to a deadbolt lock assembly and an actuation mechanism therefor. The deadbolt lock may be used in a swinging door fitted within a doorway of a building. BACKGROUND

A deadbolt is a mechanism for securing a door in a closed condition. It is referred to as 'dead' because there are no springs to operate the bolt, as there may be in a door latch mechanism. Rather, it is only operated manually with a key or, in some configurations, with a turn-snib on one side of the door. A mechanism that requires use of a key from both sides of the door is often called a double-cylinder deadbolt lock, whereas a mechanism with a turn-snib on one side is called a single-cylinder deadbolt lock.

A deadbolt mechanism may be mounted on one face of a door, or may be installed within a door structure. Where installed within a door, the bolt, in use, extends outwardly from the edge of the door to engage a corresponding strike plate installed in the door jamb. The engagement between the extended bolt and strike plate is what prevents the door from being opened when the door has been closed and locked.

For an in-door installation, whilst the bolt mechanism itself may be contained within the door structure (except for the portion of the bolt that extends, in use, from the door edge), the user operable actuators for the bolt (e.g. the lock cylinders) are generally contained in housings that sit proud of the door face. This is particularly the case for double-cylinder deadbolt locks.

It would be desirable to provide a deadbolt lock in which the actuators and/or the housings therefor do not substantially protrude from the surface of the door.

SUMMARY OF THE INVENTION

The present invention provides a deadbolt door lock assembly including a slidable bolt having a rack gear and at least one key operated lock cylinder coupled to a pinion gear that in use engages the rack gear.

The present invention also provides a deadbolt door lock assembly including a slidable bolt having an elongate form with first and second rack gears disposed on opposed sides along a length thereof, and first and second user rotatable actuators coupled to rotate respective first and second pinion gears that in use engage the respective first and second rack gears on the bolt.

According to the present invention there is also provided a deadbolt door lock assembly for installation within a door structure having first and second side faces and a door edge, the assembly comprising a deadbolt mechanism with a bolt arranged for sliding movement along a bolt axis between retracted and extended configurations wherein the bolt, in use, protrudes from the door edge when in the extended configuration, the assembly further comprising first and second actuators provided for operating the deadbolt in use, from respective sides of the door, each of the first and second actuators being contained at least substantially between the faces of the door when installed therein.

The deadbolt mechanism may include an elongate housing that supports the bolt for sliding movement along the bolt axis, the housing being mounted in use within said door structure.

The housing may in use be mounted such that the bolt axis extends substantially horizontally, wherein the first and second actuators are respectively disposed above and below the bolt axis. The bolt may be constructed to have an axially elongate form with first and second rack gears disposed on opposed sections along a length thereof, wherein the first and second actuators have respective first and second rotatable pinion gears that in use engage the respective first and second rack gears whereby rotation of the one and/or the other of the pinion gears effects axial movement of the bolt.

The first and second actuators may each comprise a key operated lock cylinder. Alternatively, the first actuator may comprise a key operated lock cylinder and the second actuator comprise a user rotatable turn-snib.

According to the present invention there is also provides a double- cylinder deadbolt door lock assembly comprising a deadbolt mechanism with a bolt arranged for sliding movement along a bolt axis between retracted and extended configurations, and first and second actuators provided for operating the deadbolt mechanism, in use, from respective sides of the door, the first and second actuators comprising respective key operated lock cylinders, wherein the axes of rotation of the lock cylinders are transverse to the bolt axis, and offset from one another so as to be disposed to opposite sides of the bolt axis.

In one form the present invention provides a deadbolt door lock assembly for installation within the structure of a hinged door having first and second side faces on either side of a vertical swinging edge that is opposite a hinged edge of the door, the assembly including:

a deadbolt mechanism adapted for installation in the door and having a bolt arranged for sliding movement along a bolt axis between retracted and extended configurations wherein the bolt, in use, protrudes from the swinging edge of the door when in the extended configuration;

a first actuator in use coupled to operate the deadbolt mechanism, the first actuator including a lock cylinder with a key rotation axis perpendicular to the bolt axis and a keyway slot accessible from the first side face of the door, the lock cylinder being, in use, at least substantially contained within the door structure between the first and second side faces; and a second actuator in use coupled to operate the deadbolt mechanism, the second actuator comprising one of:

a lock cylinder with a key rotation axis perpendicular to the bolt axis and a keyway slot accessible from the second side face of the door, the lock cylinder being, in use, at least substantially contained within the door structure between the first and second side faces; or

a user rotatable turn-snib accessible from the second side face of the door.

A deadbolt door lock assembly according to the present invention may comprise:

a deadbolt mechanism with a bolt arranged for sliding movement along a bolt axis between retracted and extended configurations, the bolt having an axially elongate form with a series of transverse rack teeth; and

first and second actuators operable from respective opposite sides of the deadbolt mechanism, the first and second actuators each having a rotatable pinion gear that in use engage the bolt rack teeth whereby rotation of the pinion gears effects axial movement of the bolt.

A deadbolt door lock assembly according to the present invention may comprise:

a deadbolt mechanism with a bolt arranged for sliding movement along a bolt axis between retracted and extended configurations, the bolt having an axially elongate form with first and second rack gears disposed on opposed sections along a length thereof; and

first and second actuators operable from opposite sides of the deadbolt mechanism, the first and second actuators having respective first and second rotatable pinion gears that in use engage the respective first and second rack gears whereby rotation of the one and/or the other of the pinion gears effects axial movement of the bolt.

In another aspect, the present invention provides a deadbolt mechanism including a housing that supports a bolt assembly for sliding motion along a bolt axis between retracted and extended configurations, the bolt assembly comprising a bolt shaft coupled to a bolt head that extends from the housing when in the extended configuration, the mechanism further including a retraction latch actuated by the bolt shaft that prevents an external force exerted on the bolt head from causing movement of the bolt from the extended configuration to the retracted configuration.

Further aspects, features and advantages of the present invention will be apparent to those of ordinary skill in the art from the accompanying description and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

In order that the invention may be more easily understood, the following detailed description is provided including description of several embodiments, presented by way of example only, and with reference to the accompanying drawings in which:

Figure 1 is an exploded view of an exemplary prior art deadbolt door lock;

Figure 2 is an end profile view of a prior art deadbolt lock installed in a door;

Figure 3 is a perspective view of a prior art deadbolt lock in isolation; Figures 4A and 4B are diagrammatic side and end views of a deadbolt lock component arrangement according to embodiments of the present invention;

Figure 5 is a diagrammatic end view of a deadbolt lock construction according to embodiments of the present invention;

Figures 6A and 6B are left and right perspective views of a deadbolt lock according to an embodiment of the invention;

Figure 7 is an upper perspective exploded view of the deadbolt lock of Figure 6;

Figure 8 is a lower perspective exploded view;

Figures 9A and 9B are side perspective views of the deadbolt lock in partial longitudinal section; Figure 10 is a side sectional view of the deadbolt lock with bolt retracted;

Figure 1 1 is a side sectional view of the deadbolt lock with bolt extended;

Figures 12A and 12B are detailed views showing engagement between the lock cylinder and pinion gear allowing limited free-wheel rotation;

Figures 13 to 16 are side sectional views of the deadbolt lock illustrating the bolt extending action;

Figures 17A and 17B are horizontal longitudinal section views of the forward portion of the deadbolt lock assembly with bolt in extended and retracted configurations, respectively;

Figures 18 to 21 are side sectional views of the deadbolt lock illustrating the bolt retracting action;

Figures 22A, 22B and 22C illustrate the use of a removable tab to ensure correct alignment of components during lock installation;

Figures 23 and 24 are transverse sectional views illustrating adjustment of the deadbolt lock for different door thicknesses;

Figures 25 and 26 are side views illustrating adjustment of the deadbolt lock for different door set-back displacements;

Figure 27 shows a user operable turn-snib that may be used in place of an internal key-lock;

Figure 28 shown the turn-snib gear mechanism; and

Figures 29 and 30 are exploded views of a deadbolt lock with a turn-snib in place of an internal key-lock.

DETAILED DESCRIPTION

A double cylinder deadbolt lock of conventional form is shown in Figures

1 , 2 and 3. Figure 3 shows the deadbolt lock 10 as assembled, but without the door structure. Figure 1 shows the prior art deadbolt lock components in exploded view, also absent the door structure. Figure 2 illustrates the deadbolt lock 10 installed in a door, as seen looking at the door edge.

The primary sub-assemblies of the conventional form of double cylinder deadbolt lock 10 can be readily seen in Figure 3. The central sub-assembly is a deadbolt mechanism 14 that is, in use, contained within the door structure (not seen in this figure). The deadbolt mechanism has a mounting plate 18 at its forward end that, when the mechanism is installed in the door, sits substantially flush with the edge surface of the door. Operation of the deadbolt mechanism causes the deadbolt 16 to extend or retract with respect to the mounting plate, and thus relative to the door itself. The deadbolt 16 is shown in its extended configuration in Figure 3. Actuation of the deadbolt mechanism 14 is effected by key operated lock sub-assemblies 22, 24 in use installed on the inside and outside surfaces of the door. A keyway slot 30 can be seen in the near side lock sub-assembly 22 for insertion of a key to operate the lock.

The deadbolt door lock assembly 10 according to the prior art can be seen in exploded view in Figure 1 , in which the components of lock subassembly 22 can be seen. The two lock sub-assemblies 22, 24 are largely similar to one another, in mirror image with respect to the central plane of the door in which the deadbolt is, in use, installed. The deadbolt mechanism 14 operates using a cam or push arm (not shown) whereby rotation of a cam slot 20 is translated to linear motion of the bolt 16. Rotation of the cam slot in one direction causes the bolt to extend, and rotation in the other direction causes the bolt to retract.

The cylinder housing assembly 22 includes a lock cylinder 28 of conventional form and having an outward facing keyway slot 30. When a corresponding key (not shown) is inserted in the lock cylinder through the keyway slot the central barrel of the lock is able to be rotated about the longitudinal axis of the lock cylinder, which is perpendicular to the axis of movement of the deadbolt. The cam bar 34 is coupled for rotation with the lock barrel, and when the deadbolt door lock is assembled the cam bar 34 is engaged in the cam slot 20 of the deadbolt mechanism. The cylinder housing assembly 24 on the other side of the door has a corresponding cam bar 36 that engages with the cam slot 20 from the other side of the deadbolt mechanism 14. Operation of the deadbolt lock assembly as described above and shown in Figures 1 -3 requires that rotation of the respective lock cylinder on either side of the door is able to rotate the cam slot 20 and thereby effect extension or retraction of the bolt 16. Thus, the two lock cylinders (one on each side of the door) are axially aligned with one another, and with the axis of rotation of the cam slot. The combined length of the two lock cylinders and width of the deadbolt mechanism is greater than the width of a normal door, which means that this configuration requires that the lock cylinders substantially protrude from the respective door faces on each side. This necessitates the convex cylinder housings 26, 27.

The implications of this configuration are well illustrated in Figure 2, which shows the conventional deadbolt door lock assembled in a door 12 as seen edge-on. Since the rotation axes 32 of the lock cylinders on each side of the door are aligned co-axially, the lock cylinders must be accommodated in housings 26, 27 that project a substantial amount (di, do) beyond the thickness (D) of the door itself. The protruding cylinder housings are unsightly and may also place some restrictions on the door function.

Embodiments of the present invention employ a different configuration in order to provide a deadbolt door lock assembly that can be wholly, or at least substantially, contained within the width of the door in which it is installed. Figures 4A, 4B and 5 illustrate the general arrangement of the deadbolt door lock sub-assemblies according to embodiments of the invention that enable the 'low-profile' construction of the lock. The arrangement is explained further hereinbelow, followed by more detailed description of several specific mechanisms and assemblies that may embody the invention.

On a note of terminology, features of the deadbolt lock assembly, mechanisms and components may be described herein using reference to relative orientations or directions such as left/right, upper/lower, forward/back, and the like. In general such terms are to be understood as referring to the assembled deadbolt lock as if it were installed in a door, where the direction in which the bolt extends is considered the 'forward' direction. Thus, considering the bolt extension direction as forward, the door has left and right faces.

In the description that follows, with regard to door structures in which the deadbolt lock may be installed, reference may also be made to the 'inside' or 'internal' and 'outside' or 'external' which are commonly used terms that delineate features that lie to one side or the other of the doorway. It should be appreciated these terms are generally used in a relative sense that does not necessarily imply or import other meanings or features unless clearly stated. Moreover, when considering the door having a forward direction as defined by the bolt extension, the left-hand side may be the 'inside' and the right-hand side may be the 'outside', or vice versa.

Certain features of the deadbolt lock are similar on both sides of the door when installed. For example, in a double cylinder deadbolt lock each side of the door has a respective lock cylinder that can be user-operated from that side of the door. For ease of reference, similar features of the embodiments that are provided on each side of the door are designated by a reference numeral followed by a suffix 'A' or 'B' corresponding to respective sides of the door. It will be appreciated that A or B may arbitrarily correspond to left or right, inside or outside, unless otherwise stated.

A deadbolt door lock assembly configuration is according to embodiments of the invention is shown in Figures 4A, 4B and 5 in which the axis of rotation of the actuators from each side of the door are offset with respect to one another, above and below the bolt. In the case of a double cylinder lock (i.e. actuation through rotation of a key from either side of the door), the axis of key rotation is offset, as shown in Figure 5. Specifically, Figure 5 illustrates the deadbolt lock assembly 100 installed in a door 102 viewed looking at the edge of the door showing the mounting plate 1 15 and the forward end of the bolt 120. The key for actuation of the lock on one side (in this case the right-hand side of the door, although it is the left-hand side of the diagram) has a corresponding actuator (e.g. lock cylinder) with an axis of rotation indicated at 150A. On the other hand, the other side of the lock assembly has an actuator with an axis of rotation indicated at 150B. This arrangement, with the axis of one actuator above the bolt and the other below it, allows the lock assembly to be at least substantially contained within the width D of the door 102. Thus, the overall width of the deadbolt door lock assembly is substantially decreased, as compared to the prior art shown in Figures 1 -3, for example, in which the actuator/key axes are aligned.

Figures 4A and 4B diagrammatically illustrate the configuration of the low-profile deadbolt door lock assembly and actuation mechanism 100 from the side and from the front, respectively. The assembly 100 includes a deadbolt mechanism 1 10 that is in use mounted in a door (not shown) with a forward surface of the mounting plate 1 15 flush with the edge of the door. The deadbolt mechanism is operative to extend and retract a bolt (bolt 120 shown in Figure 4A in its extended configuration in dashed lines). Operation of the deadbolt mechanism is effected by actuators 130A and 130B that may be manipulated by a user from either side of the door. In the case of a double cylinder lock as shown here each actuator has a lock cylinder 132A, 132B that is operated by means of a key inserted in the respective keyway slot 135A, 135B from the side of the door corresponding to that actuator.

As shown in these figures, the lock cylinder 132A for one side of the door is positioned above the deadbolt mechanism, and the lock cylinder 132B for the other side of the door is positioned below the deadbolt mechanism. This configuration allows the lock cylinders to be installed within the width of the door, rather than protruding from the door surface. The lock assembly components are concealed by a faceplate 140A, 140B on each side of the door, for example, which may be mounted substantially flush with the door surface. The keyway slot 135A for operating the lock assembly from one side is positioned toward the top of its faceplate 140A, whilst the keyway slot 135B on the other side is positioned toward the bottom of its faceplate 140B.

An embodiment of the low-profile deadbolt assembly and actuation mechanism in the form of a double cylinder deadbolt door lock assembly 200 is shown in various views in Figures 6 to 29 in order to illustrate its construction, components, features and modes of operation, to which reference is made to the detailed description hereinbelow.

The double cylinder deadbolt door lock assembly 200 is seen in perspective from upper right and lower left-hand views in Figures 6A and 6B, respectively. The assembly 200 comprises generally a deadbolt mechanism 210 that supports linear motion of the bolt 250 between retracted and extended configurations. In these drawings the bolt is shown in the retracted configuration where its end surface is flush with the surface of mounting plate 222. The assembly 200 also comprises left and right key operated actuator mechanism assemblies 300A, 300B. The left actuator mechanism assembly 300A has a faceplate 321 A with an aperture in the lower portion thereof that provide access to a keyway slot 366A for operating a left-side lock cylinder 360A. Conversely, the right actuator mechanism assembly 300B has a faceplate 321 B with an aperture in the upper portion thereof that provide access to a keyway slot 366B for operating a right-side lock cylinder 360B. When installed in a door (not shown in these drawings) the front surface of the deadbolt mechanism mounting plate 222 would be substantially flush with an edge surface of the door, whilst the actuator assembly faceplates 312A, 321 B would be substantially flat against the respective left and right door surfaces, generally adjacent the edge of the door with the mounting plate 222.

Figures 7 and 8 show the double cylinder deadbolt door lock assembly 200 in exploded views from upper and lower perspectives. As indicated in Figure 7, the primary sub-assemblies of the assembly 200 comprise the deadbolt mechanism 210 that includes bolt housing 220 and deadbolt 250, and the left and right key operated actuator mechanism assemblies 300A, 300B. Figure 8 more particularly indicates a number of the various components of the assembly 200, which are described below.

The bolt housing 220 has a generally hollow-tubular configuration with a flange at its forward end forming the mounting plate 222. The mounting plate 222 has a central bolt head aperture 226 that is aligned with the longitudinal hollow interior of the housing, and two mounting hardware holes 224 for securing the mounting plate, in use, to the edge of a door using screws or the like. The housing 220 is dimensioned to accommodate the deadbolt 250 therewithin, and allow an amount of longitudinal sliding motion of the deadbolt relative to the housing so as to enable the bolt to move between extended and retracted configurations as described in detail below.

The deadbolt 250 has an elongate shape comprising a shaft portion 260 and a head portion 280 at its forward end. The upper and lower surfaces of the shaft portion are generally planar but with a series of evenly spaced transverse notches formed therein to create upper and lower bolt racks 262, 264. The head portion 280 is actually a separate component that is attached to the shaft portion 260, as will be described further hereinbelow.

With the deadbolt 250 received within the housing 220 and the bolt in its retracted configuration, the bolt head end surface 282 lies substantially flush with the forward surface of the mounting plate 222. The upper and lower bolt racks 262, 264 are exposed by upper and lower rack interface 230, 232 in the form of apertures mid-way along the length of the bolt housing 220.

The left and right actuator assemblies 300A and 300B are generally similar to one another, although one has its operative components positioned to lay below the deadbolt 250 (when assembled) and the other above. For convenience the following description of components shown in Figure 8 predominantly references those from the left-hand actuator assembly 300A. Nevertheless, except where differences are explicitly noted, it will be appreciated that the right-hand actuator assembly 300B includes equivalent components. Accordingly, the reference numerals in Figure 8 are not suffixed by designations Ά or 'B' to avoid confusion.

Each actuator assembly 300 includes a housing 310. The housing on one side has a pair of installation bolt receiver formations 318 that are adapted to receive corresponding installation bolts 316 inserted through the housing on the other side, to secure the two housings together with the deadbolt mechanism in between. Specifically, it is the housing that is adapted for installation on the external side of the door that has the bolt receiver formations 318, whilst the housing adapted for installation on the internal side of the door is provided with the bolts 316. This allows the bolts to only be accessible from the internal, secure side of the door, so the lock cannot be disassembled or removed from the external, non-secure side.

When the housings are secured together the installation bolt receivers

318 lay in transverse slots 235 in the bolt housing, adjacent the rack interface apertures 232. Complementary alignment formations 319 that project from the housings on each side also lay in corresponding slots 235. Engagement between the bolt receivers and alignment formations 318, 319 with the transverse slots 235 ensure correct alignment between the actuator assemblies 300 and deadbolt mechanism 210 when assembled and installed.

The housing 310 includes a lock cylinder receiver 320 that is adapted to secure the lock cylinder 360 therein by use of a location screw 322. When the lock cylinder is secured in the housing the keyway slot 366 is accessible through a lock aperture 31 1 . When the assembly 200 is installed in a door, the housing 310 on each side is covered by a faceplate 312 having a faceplate aperture 313 corresponding to the lock aperture 31 1 . The faceplate 313 may be held to the housing, for example, through the use of one or more magnets 315. In practice the faceplate on the external side of the lock may be affixed in a non-removable manner, and that on the internal side attached magnetically, since it is only the internal faceplate that should be removable to access the bolts 316.

The lock cylinder 360 is part of a lock mechanism 350 that is the operative part of the actuator. The lock cylinder 360 is held by the housing 310 and has a rotatable keyed barrel 362. The lock cylinder is generally conventional in its operation, allowing the barrel to be rotated only when a key is inserted in the keyway slot 366 that has a shape configured to correspond to the particular configuration of pins arranged in the pin housing 368.

The other end of the lock barrel from where the key is inserted (barrel end 364) is adapted to coaxially receive a pinion gear 380 that is secured on the barrel end 364 by a spring clip 382. The pinion gear is fitted to rotate with the lock barrel, although with a range of free-wheel motion, as explained further hereinbelow. The pinion gear 380 has gear teeth arranged around its external circumference, the pitch of the teeth corresponding to the transverse notches formed in the upper and lower bolt racks 262, 264 of the deadbolt 250.

When the lock assembly 200 is installed, the pinion gear of one actuator mechanism 300 meshes with the upper bolt rack 262 in the region of the upper rack interface 230, and the pinion gear of the other actuator mechanism meshes with the lower bolt rack 264 in the region of the lower rack interface 232. This is best seen in Figures 9A and 9B which are side perspective views of the deadbolt lock assembly 200 with the nearside (in this case left-hand side) housing removed and bolt housing 220 shown in longitudinal section. Here the right-hand side housing 310B is shown assembled with the deadbolt mechanism and fitted with its lock mechanism wherein the barrel end 364B can be seen fitted with pinion gear 380B and securing clip 382B. The teeth of pinion gear 380B are seen meshed with the grooves formed in the upper bolt rack 262. Similarly the left-hand side lock mechanism can also be seen, including lock cylinder 360A and the key insertion end of rotatable barrel 362A. Although partially obscured, the relationship of the pinion gear 380A and lower bolt rack 264 can be appreciated as being similar to that between pinion gear 380B and the upper bolt rack.

For the purpose of explaining the general mode of operation of the deadbolt lock the assembly 200 is shown in Figures 10 and 1 1 in vertical longitudinal cross-section with the bolt in retracted and extended configurations, respectively. Considering the nearside lock mechanism 350B, in order to move the bolt from the retracted configuration (Figure 10) to the extended configuration (Figure 1 1 ) a key (not shown) is inserted into keyway slot 366B and rotated in a clockwise direction. This has the effect of rotating the lock barrel 362B in the clockwise direction, causing clockwise rotation of the pinion gear 380B. Since the pinion gear 380B is meshed with the lower bolt rack 264, the rotational movement of the gear causes linear translation of the deadbolt shaft 260 within the bolt housing 220. This results in the bolt shaft pushing the bolt head 280 to the right (as seen in the drawings) until the bolt is fully extended as shown in Figure 1 1 . Conversely, retraction of the bolt may be effected by rotation of the lock cylinder barrel 362B in the opposite, counterclockwise direction.

As can be seen in Figures 10 and 1 1 , while the lock barrel 362B is rotated to extend the bolt the other lock barrel 362A is able to remain stationary. This is permitted by the aforementioned range of free-wheel motion between the pinion gear and the lock barrel, the arrangement of which is explained with reference to Figures 12A and 12B. Figure 12A shows a lock mechanism 350 in isolation, including the lock cylinder 360 with pin housing 368, and the lock barrel 362 with its barrel end 364 fitted with pinion gear 380 and securing clip 382. Figure 12B shows a transverse cross-section through the pinion gear 380 mounted on the barrel end 364 that illustrates how the barrel engages the gear for rotation. The pinion gear is supported for free rotational movement coaxial with the lock barrel end 364, within the confines defined by an engaging tab 390 that projects radially inward from the ring-shaped pinion gear within a freewheel slot 391 . The circumferential extent of the freewheel slot 391 is defined by clockwise and counter-clockwise gear engaging shoulders 392, 393 formed on the barrel end 364. Thus, from the configuration shown in Figure 12B, the gear 380 would be able to freely rotate (i.e. separately from the lock barrel) in the clockwise direction until the tab 390 on the inside of the gear meets the shoulder 393 on the outside of the barrel end. On the other hand, if the lock barrel were to be rotated in the clockwise direction the engaging shoulder 392 would bear against the tab 390 and cause the gear 380 to also rotate.

As mentioned, the construction of the lock mechanism 350 in which the pinion gear has a range of freewheel rotation with respect to the lock barrel allows the lock assembly 200 to be operated by one lock cylinder without the other lock cylinder rotating. This allows the internal and external locks to be operated independently of one another, allowing the bolt to be locked or unlocked either externally or internally, in use. However, since the gears need to be able to freewheel to a controlled degree it is preferred for the assembly to incorporate a mechanism to prevent the bolt from being able to be pushed back from the extended position into the retracted positon. Such a mechanism, and its operation, is described below in connection with Figures 13 to 16.

Figures 13 to 16 show the deadbolt lock assembly 200 in vertical longitudinal section in incremental stages from a configuration in which the bolt is fully retracted (Figure 13) to a configuration in which the bolt is fully extended and locked in place (Figure 16). The bolt head 280 as seen in these drawings is formed with a rearward facing internal cavity 281 adapted to accommodate the forward end 261 of the bolt shaft 260. A slot 265 formed in the bolt shaft forward end has a vertical bolt head pin 284 projecting therethrough, the ends of the pin 284 being secured in the top and bottom of the bolt head 280 across the cavity 281. This arrangement allows a limited amount of relative linear translation as between the bolt shaft and bolt head for the purposes as explained below.

The deadbolt mechanism also includes a ball bearing 285 that sits on the inside face of the bolt housing 220, captured in a cavity formed between a profiled track 267 in the bolt shaft and a rear edge 286 of the bolt head 280. The profiled track 267 is narrowed toward the rear with a shoulder 268 between the enlarged forward end and the narrowed rear end. The ball bearing 285 is free to roll along the inside face of the bolt housing within the cavity as the bolt is projected forward through operation of the rack and pinion mechanism.

When the bolt shaft 260 is projected forward by action of one or other of the pinion gears, the shoulder 268 bears on the ball 285 which in turn bears on the rear edge 286 of the bolt head, forcing the bolt head 280 to also project forward (Figure 14). As the bolt shaft moves forward the ball bearing 285 reaches the edge of a ball locking depression 236 formed in the lower inside of the housing 220. Further forward motion of the bolt shaft causes the ball bearing 285 to drop into the depression 236, as seen in Figure 15. The result of this is that the top of the ball 285 drops below the level of the shoulder 268, whereby the bolt shaft is unable to exert further forward force on the ball and on the bolt head. At this point the bolt head 280 is fully extended and is also prevented from projecting further by means described below in connection with Figures 17A and 17B.

As the bolt shaft is driven further forward, the shoulder 268 passes over the top of the ball 285. The ball 285 remains captured in the depression 286, and the bolt head remains stationary as the bolt shaft forward end extends further into the bolt head cavity 281 . The final, locked configuration of the assembly 200 is shown in Figure 16, wherein the ball 285 is held in the depression 286 by the narrowed end of the profiled track 267. In this configuration the bolt head is prevented from being pushed backwards by an external force by the ball bearing 285 which is unable to move out of the depression because of the narrowed profile track. The ball bearing can only be released by drawing the bolt shaft back, which is described hereinbelow in connection with Figures 18-21 .

Figures 17A and 17B show the forward portion of the deadbolt lock assembly 200 in horizontal longitudinal section which is useful for illustrating several features not visible in the previous views. Figure 17A shows the bolt in its extended configuration, while Figure 17B shows the retracted configuration, in each case with the assembly installed in a door 102. Figure 17A particularly shows the mechanical arrangement designed to prevent the bolt head from exiting the front of the assembly. Specifically, the rear of the bolt head 280 is formed with an outward flange 287. The flange 287 extends beyond the aperture formed in the mounting plate 222 through which the bolt head projects, thereby preventing the bolt head from projecting past its intended extent. Figure 17B shows another mechanical feature that acts between the bolt housing and the bolt head, in this case a leaf spring 240 between the inside of the housing 220 and the outside surface of the bolt head 280. The leaf spring 240 is included to provide a frictional force against the bolt head to prevent it, for example, from inadvertently extending forward when the door is swung with excessive force.

Figures 18 to 21 show the deadbolt lock assembly 200 in vertical longitudinal section in incremental stages from a configuration in which the bolt is fully extended and locked in place (Figure 18) to a configuration in which the bolt is fully retracted (Figure 21 ). Figure 18 is similar to Figure 16 in that the bolt is fully extended and locked in place, although it can be seen that the key barrel 362B has been returned to a 3-o'clock position, which is the orientation that permits the key to be inserted and removed from the keyway slot 366B. The key barrel 362B is able to move from the Figure 16 orientation to the Figure 18 orientation without rotating the corresponding pinion gear 380B because of the limited free-wheel mount of the gear as described previously.

In order to retract the bolt, to unlock the door in which it is installed for example, the key is inserted in keyway slot 366B and rotated in a counterclockwise direction. This causes corresponding rotation of the pinion gear 380B which acts upon the lower rack to draw the bolt shaft backward (to the left of the drawing). Initially, with the bolt fully extended and locked (Figure 18), the end 261 of the bolt shaft 260 is at its furthest forward extent into the bolt head cavity, wherein the bolt head pin 284 is positioned to the rear of the slot 265 in the end 261 of the bolt shaft.

As the bolt shaft is drawn back, the bolt head initially remains stationary until the forward end of the slot 265 reaches the pin 284 (Figure 19). Further backward motion of the bolt shaft 260 therefore causes the bolt shaft end 261 to bear against the pin 284, transferring force to the bolt head 280. By this point the bolt shaft 260 has retracted to an extent where the profiled track 267 has its enlarged forward end positioned over the ball bearing 285. As the bolt shaft is retracted further still, drawing the bolt head with it, the bolt head rear edge 286 bears against the ball 285 forcing it toward the rear of the assembly and out of the depression 236 (Figure 20). The ball 285 is allowed up out of the depression due to the shape of the profiled track 267, whereupon the ball 285 is able to freely roll along the lower inside surface of the bolt housing 220 as the bolt shaft and bolt head retract. The fully retracted configuration is shown in Figure 21 , although to remove the key from the lock cylinder the user must return the key barrel 362B to where the keyway slot 366B is in the 3-o'clock orientation, as previously explained. During installation of the deadbolt lock assembly 200 into a door, the three main sub-assemblies are normally put together by inserting them from different sides of the door (after making the appropriate apertures in the door structure). For example, the deadbolt mechanism 210 may be inserted from the edge of the door and secured through the mounting hardware holes 224. Then, the internal and external actuator assemblies are inserted from their respective sides of the door to interface with the deadbolt mechanism. In this assembly process it is important that the respective key barrels and pinion gears are correctly oriented and mesh with the upper and lower racks in the correct location. For this reason the lock mechanisms 350 may be initially fitted with a removable tab 355 that correctly aligns the gear 380 with the keyway slot 366 for assembly with the deadbolt mechanism with the bolt retracted.

The removable tab 355 is shown in Figures 22A, 22B and 22C. Figure 22A shows the tab 355 inserted in the keyway slot 366 of the lock mechanism with a portion projecting out. This arrangement places the lock mechanism in a condition where the barrel and pinion gear are correctly aligned for installation and engagement with the deadbolt mechanism. Figure 22B shows the assembly from the other side with the clip 382 and gear 380 removed so that the other end of the tab 355 can be seen. The tab 355, when in place, holds the keyway slot in alignment with the gear 380 by engaging in a notch 381 formed in the gear for this purpose, preventing free-wheel motion of the gear. Once the gear 380 has been correctly engaged with the rack, the tab 355 may be removed as seen in Figure 22C. The tab 355 as shown has an elongate form to extend along the length of the keyway slot, and has a slight bowed shape for frictional engagement in the slot while in place.

The deadbolt door lock assembly 200 has a construction that enables it to be readily installed in doors over a range of different thicknesses. To illustrate this feature Figures 23 and 24 each show a door lock assembly 200 in vertical transverse section installed in a door of different thickness. The door 102' in Figure 23 is relatively thin, and the door 102" is relatively thick. The upper and lower bolt racks 262, 264 carried by the bolt shaft 260 has a transverse width that allows the respective pinion gears to engage therewith across a range of alignments. For example, when installed in a thin door 102' (Figure 23) the left and right pinion gears 380A, 380B are aligned toward opposing edges of the lower and upper bolt racks 264, 262, respectively. On the other hand, when installed in a thicker door 102" (Figure 24) the pinion gears 380A, 380B are aligned toward the centre of the width of their respective racks 264, 262.

Figures 25 and 26 illustrate another mode of adjustability that the deadbolt lock assembly 200 is capable of, allowing for different offset displacements from the door edge. For example, it can be seen from these drawings that the lock cylinder 360 has a greater offset from the mounting plate 222 in Figure 25 than in Figure 24. This is enabled by a longitudinally slidable 'telescopic' section 221 of the bolt housing 220.

The embodiments described hereinabove have been double-cylinder deadbolt door lock assemblies, in which the actuator on each side of the door includes a key operated lock cylinder. However in some circumstances it is desirable to have a so-called privacy configuration in which the internal actuator is operated by a snib, knob or lever, rather than requiring a key. Accordingly, Figures 27 and 28 illustrate a user operable turn-snib mechanism 400 that may be employed in the deadbolt door lock assembly according to embodiments of the present invention, in place of an internal key operated lock.

Figure 27 is a perspective view of the turn-snib mechanism 400 from an aspect that shows the user operable, rotatable snib 440 and faceplate 412. Figure 28 is a perspective view that shows the turn-snib mechanism 400 from the other side, illustrating components that are contained within the door structure once the assembly is installed. Specifically, a turn-snib housing 410 is provided that is generally similar to the lock housing it replaces, and includes features enabling it to be correctly located and secured in relation to the lock housing on the other side of the door, and the deadbolt mechanism. The housing 410 holds magnets 415 that are used to secure the faceplate 412 without the use of adhesives or fasteners. When the mechanism 400 is installed in a door, the faceplate is parallel to the door face, protruding a small amount from the surface.

The snib 440 is located in the centre of the circular faceplate and housing and mounted for rotation about an axis perpendicular to the faceplate plane. The snib 440 has an axial shaft (not seen) that projects through the centre of the housing to which a central gear 450 is mounted (Figure 28). The central gear 450 engages with an offset gear 460 that is mounted for to the housing 410 for rotation about a parallel axis. A gear shaft 470 is axially mounted on the offset gear 460, and a pinion gear 480 is mounted on the other end of the gear shaft 470. The pinion gear 480 is arranged in relation to the turn-snib housing 410 in a similar manner as the pinion gear 380 is arranged in relation to the lock housing 310 previously described. This allows the pinion gear 480 to engage with one of the upper and lower bolt racks when assembled with the deadbolt mechanism. When so assembled, user rotation of the snib 440 rotates the central gear 450 which engages with the offset gear 460 to in turn rotate the shaft 470 and pinion gear 480 which acts on the bolt rack to extend or retract the bolt, depending on the direction of rotation.

Figures 29 and 30 are perspective exploded views of a deadbolt lock assembly 500 with a turn-snib actuator 400 in place of an internal key-lock actuator. In the assembly 500 as shown it can be seen that the pinion gear 480 of the turn-snib mechanism is arranged to engage with the lower bolt rack 264, when the deadbolt assembly is assembled and installed.

The invention has been described by way of non-limiting example only and many modifications and variations may be made thereto without departing from the spirit and scope of the invention.

The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates. Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

Claims

1 . A deadbolt door lock assembly for installation within a door structure having first and second side faces and a door edge, the assembly comprising a deadbolt mechanism with a bolt arranged for sliding movement along a bolt axis between retracted and extended configurations wherein the bolt, in use, protrudes from the door edge when in the extended configuration, the assembly further comprising first and second actuators provided for operating the deadbolt in use, from respective sides of the door, each of the first and second actuators being contained at least substantially between the faces of the door when installed therein.

2. A deadbolt door lock assembly according to claim 1 wherein the deadbolt mechanism includes an elongate housing that supports the bolt for sliding movement along the bolt axis, the housing being mounted in use within said door structure.

3. A deadbolt door lock assembly according to claim 2 wherein the housing is in use mounted such that the bolt axis extends substantially horizontally.

4. A deadbolt door lock assembly according to claim 3 wherein the first and second actuators are respectively disposed above and below the bolt axis.

5. A deadbolt door lock mechanism according to claim 4 the bolt having an axially elongate form with first and second rack gears disposed on opposed sections along a length thereof; and

the first and second actuators having respective first and second rotatable pinion gears that in use engage the respective first and second rack gears whereby rotation of the one and/or the other of the pinion gears effects axial movement of the bolt.

6. A deadbolt door lock mechanism according to any one of claims 1 to 5 wherein the first and second actuators each comprise a key operated lock cylinder.

7. A deadbolt door lock mechanism according to any one of claims 1 to 5 wherein the first actuator comprises a key operated lock cylinder and the second actuator comprises a user rotatable turn-snib.

8 A double-cylinder deadbolt door lock assembly comprising a deadbolt mechanism with a bolt arranged for sliding movement along a bolt axis between retracted and extended configurations, and first and second actuators provided for operating the deadbolt mechanism, in use, from respective sides of the door, the first and second actuators comprising respective key operated lock cylinders, wherein the axes of rotation of the lock cylinders are transverse to the bolt axis, and offset from one another so as to be disposed to opposite sides of the bolt axis.

9. A deadbolt door lock assembly for installation within the structure of a hinged door having first and second side faces on either side of a vertical swinging edge that is opposite a hinged edge of the door, the assembly including:

a user rotatable turn-snib accessible from the second side face of the door.

10. A deadbolt door lock assembly comprising:

1 1 . A deadbolt door lock assembly comprising:

12. A deadbolt door lock assembly including a slidable bolt having a rack gear and at least one key operated lock cylinder coupled to a pinion gear that in use engages the rack gear.

13. A deadbolt door lock assembly including a slidable bolt having an elongate form with first and second rack gears disposed on opposed sides along a length thereof, and first and second user rotatable actuators coupled to rotate respective first and second pinion gears that in use engage the respective first and second rack gears on the bolt.

14. A deadbolt mechanism including a housing that supports a bolt assembly for sliding motion along a bolt axis between retracted and extended configurations, the bolt assembly comprising a bolt shaft coupled to a bolt head that extends from the housing when in the extended configuration, the mechanism further including a retraction latch actuated by the bolt shaft that prevents an external force exerted on the bolt head from causing movement of the bolt from the extended configuration to the retracted configuration.