DESCRIPTION

[0047] As used herein, the term “deadbolt” means an exit device component having an elongated end which projects from a free end of a door in an extended position, is withdrawn into the exit device in a retracted position by action of the exit device, and extends into a hole provided in the strike or keeper when the door is closed for securing the door in the closed position.

[0048] An embodiment of the invention is shown in FIG. 1 and is generally designated 10 . The exit device of the present invention is adapted to be mounted on a door and comprises an elongated housing 12 with a press bar 14 and a latch cover 16 . Out of the latch cover extends a deadbolt 18 , a retractor blade 20 , as shown, and a deadlocking plunger 100 .

[0049] As seen in FIG. 2 with the latch cover 16 removed, the latch actuator comprises a base plate 22 having side plates 24 and 26 . Parallel to and spaced above the base plate 22 is a blade pivot pin 28 which is sturdily secured between the side plates 24 , 26 . Pivotally mounted on the pin 28 is the retractor blade 20 which comprises an enlarged hub 30 with a transverse bore accepting the pin 28 and a thin blade portion 32 having a keeper contact surface 32 a.

[0050] Disposed under the retractor blade 20 and resting on the base plate 22 is the deadbolt 18 which has on its forward upper surface a separate longitudinal cut-out 34 loosely receiving the blade portion 32 . Spaced back from the front end of the deadbolt the cut-out 34 is enlarged laterally and receives an insert 36 preferably of sintered metal. As shown, the insert is formed with an inclined wall 38 . The rearward end of the retractor blade 20 is formed with a nose 40 which butts against the surface of the inclined wall 38 . The periphery of the blade portion 32 extends forward from the nose 40 in an arc 42 concentric with the axis of the pin 28 . The arc transforms partway forward from the nose into a straight line 44 .

[0051] The insert 36 backs up on a pair of spaced shoulders 46 on either side of a longitudinal cut-out 48 ( FIG. 7 ) midway along the length of the deadbolt. The cut-out 48 is formed with opposed faces 50 which jog inward spaced from the bottom of the bolt to present flanges 52 . The flanges in their inner most faces are spaced from each other and parallel thereto. Upwardly facing shoulders 52 a are presented on top of the flanges.

[0052] Spaced back from the front end of the deadbolt its undersurface is upwardly recessed as at 54 from its midsection to its rear end. The base plate 22 is formed with a window 56 and a bolt plate 58 having a downward offset 60 dipping into the window 56 which overlies the base plate 22 from the window 56 rearward.

[0053] Surmounting the bolt plate 58 is a T-shaped deadbolt stabilizer 62 ( FIG. 9 ). The three elements: base plate 22 , bolt plate 58 and the T-shaped stabilizer 62 are clampingly secured together by a pair of bolts 64 which extend through apertures in the stabilizer 62 and the bolt plate 58 and are threaded into the base plate holes 66 . A mounting plate 68 ( FIG. 7 ) is secured to the base plate 22 and has an opening 70 therein to pass the front end of the deadbolt 18 .

[0054] The retractor blade 20 has extending laterally form its nose area 40 a lug 72 ( FIGS. 2,8 ) which provides a connection for interrelated movement between the retractor blade 20 and the deadbolt 18 . As best shown in FIG. 7 , the insert 36 which nestles in its recess in the deadbolt has rear wall 36 a, side wall 36 b and a partial front wall 36 c.

[0055] While the front end of the deadbolt is partly retained in position by the configuration of the opening 70 in the mounting plate 68 , the rear end is stabilized by the stabilizer 62 . As shown best in FIG. 9 , the flanges 62 a comprising the upper portion of the T-shaped stabilizer 62 overlie at the upwardly facing shoulders 52 a on flanges 52 in the cut-out 48 at the rearward end of the deadbolt. Thus, the deadbolt is able to travel in a controlled longitudinal direction from extended to retracted position and back again.

[0056] As shown in FIGS. 2 and 3 , the retraction of the deadbolt may be driven by the retractor blade 20 as its lobe 30 a is raised by linkages to be described. As the nose 40 of the retractor blade 20 drives into the rear wall 36 a of the insert 36 it moves the deadbolt toward retracted position. Engagement of the lug 72 with the front wall 36 c of the insert, assures that the retractor blade will not extend when the deadbolt is retracted.

[0057] When there is an inward force on the deadbolt all during the relative movement of the retractor blade 20 and the deadbolt 18 , the periphery surface 42 of the retractor blade bears on the bearing surface floor 34 a of the cut-out 34 . Thus, the great bearing force tending as in the panic situation described above to move the deadbolt from its bolt plate 58 is countered by the reaction of the surface 42 of the retractor blade 20 against the floor 34 a and the pivot pin 28 .

[0058] Part of the linkage between the press bar and the retractor blade 20 is a retractor lever 80 . This is pivoted intermediate its ends on a pin 82 sturdily bridging between the side plates 24 , 26 rearward of the retractor blade. The upper surface of the leftward side ( FIG. 2 ) of the retractor lever 80 is shaped to engage and press underneath the lobe 30 a of the retractor blade 20 so that when the rightward side of the retractor lever 80 is depressed, the leftward side urges the lobe 30 a upward, rotating the retractor blade in counter-clockwise motion as seen in FIG. 2 .

[0059] A parallel pair of ears 84 extend upward from the base plate 22 to the rightward side of the side plates 24 , 26 ( FIG. 2 ). These ears are formed with aligned openings in which is secured a pin 85 . To the pin 85 is pivotally secured a dog-bone lever 88 which has a leftward side through which extends a pin 90 . Pivoted links 92 extend on either side of the lever 80 and dog-bone lever 88 connecting the pin 90 and a pin 94 , the latter extending through the rightward end of the retractor lever 80 .

[0060] Downward motion of the rightward side of lever 80 is accomplished when the press bar is pushed in as in opening the door. The press bar has a pair of fingers 86 ( FIG. 7 ) and these engage the upper side of the extensions of pin 90 . The downward side of the dog-bone lever 88 includes a headed projection 96 as is well known in the art by which the outside cylinder or other operator for the exit device may actuate the deadbolt. The connection between the outside cylinder and the headed projection 96 will not be described herein, it being well disclosed in the Heid patent mentioned above.

[0061] Deadlocking plunger 100 operates in a manner well known in the art. Briefly, it is an elongated element which is contiguous to a side of deadbolt 18 ( FIG. 8 ). It moves or is moved from an extended position shown in FIG. 4 to a retracted position shown in FIG. 5 . Intermediate its ends it is formed with a foot 102 which fits into the recess 54 on the underside of the deadbolt 18 ( FIG. 2 ). Otherwise, the deadlocking plunger is stabilized by the inner side of the side plate 26 and the shape of the opening in the cover 16 as shown in FIG. 1 and as is conventional.

[0062] The deadlocking linkage includes a pin 104 which extends between the side plates 24 , 26 and journals the yoke 106 which is of U-shape having an elongated bight 108 ( FIG. 9 ) and upward legs 110 , 112 . The leg 112 has a long forward extension forming a deadlocking arm 114 for effecting deadlocking of the deadbolt ( FIG. 4 ). For this purpose, the distal end of the deadlocking arm 114 has a downward toe 116 and a downwardly facing notch 118 which includes a blocking surface 120 for deadlocking of the deadbolt when the deadbolt is in the keeper as will be described below. Leg 112 also has an upward drive arm 122 ( FIG. 4 ) terminating in a cam surface 124 including an inclined portion 124 a and a generally vertical portion 124 b.

[0063] The deadlocking plunger 100 is formed with a trapezoidal upward cam 126 ( FIG. 4 ) intermediate its ends, and the retractor lever 80 is formed with a transverse pin 128 , the trapezoidal cam 126 and the transverse pin 128 forming first and second actuator means, respectively, for the deadlocking linkage as will be explained. Beefy deadlocking pin 130 extends out transversely from the deadbolt 18 ( FIG. 4 ).

[0064] Various springs are provided. A torsion spring 136 winds around the pin 28 on the leftward side of the deadbolt 18 ( FIG. 7 ). One end of the spring 136 rests under the pin 82 and the other end engages under a pin 138 which extends out from the leftward side of the deadbolt 18 ( FIG. 7 ). The spring 136 is under stress so that it biases the deadbolt 18 in the extended position, and pin 138 additionally provides a stop, hitting against the mounting plate 68 to limit the extension of the deadbolt.

[0065] Spacer 140 surrounds the pin 28 on the rightward side of the hub 30 of the retractor blade and a smaller spacer 142 ( FIG. 8 ) is disposed between the spring 136 and the leftward side of the hub 30 , both to suitably position the retractor blade 20 so that the blade portion 32 is aligned with the cutout 34 in the deadbolt.

[0066] A second spring 144 ( FIG. 7 ) is a torsion spring which is disposed about the deadlocking linkage pin 104 . Its purpose is to bias the deadlocking arm 114 downward so that the notch 118 receives the pin 130 . One end of the spring 144 engages over the top of the arm 114 while the other end engages the rear surface of the deadlocking plunger 100 . The spring 144 is under stress to bias the arm 114 as described. The other end of the spring 144 pushes outward against the deadlocking plunger 100 .

[0067] A third torsion spring 150 ( FIG. 7 ) biases the dog-bone lever in a clockwise direction ( FIG. 4 ).

[0068] The general operation of a deadlocking mechanism is well known to those skilled in the art. In the embodiment described, when both the deadbolt 18 and the deadlocking plunger 100 are extended ( FIG. 4 ), the trapezoidal cam 126 of the plunger engages the toe 116 of the deadlocking arm 114 to hold the notch 118 and blocking surface 120 up clear for canceling the deadlocking action of the deadlocking arm 114 and allowing for the rearward movement of the deadbolt pin 130 . The deadbolt, thus, is free to retract on the closing of the door, being driven by the engagement of the keeper roller K ( FIG. 2 ) with the curved front keeper contact surface 32 a of the blade portion 32 . In this scenario, the keeper roller K forces the retractor blade in counterclockwise direction so that its nose 40 engages the surface of the inclined wall 38 of the insert 36 which is part of the deadbolt and drives the latter toward retracted position. Engagement of the front end surface of recess 54 in the underside of the retracting deadbolt with the foot 102 on the plunger drives back the deadlocking plunger 100 . Once the deadbolt is past the keeper roller K, it snaps outward being driven out by spring 136 to lock the door.

[0069] Because the opening in the keeper permits the intrusion of the deadbolt 18 but not the deadlocking plunger 100 , the latter cannot extend and, hence, the cam 126 is rearward of the toe 116 ( FIG. 6 ) and the deadlocking arm 114 rests with the top of the notch 118 on the pin 130 so that attempts to violate the lock by forcing the deadbolt inward are frustrated as the pin 130 hits the blocking surface 120 . Recess 54 which encloses foot 102 on the deadlocking plunger 100 is long enough to permit the deadbolt to extend while the deadlocking plunger 100 is held by the strike in depressed or nearly depressed condition.

[0070] Upon the actuation of the press bar 14 , the pins 86 ( FIG. 7 ) press the ends of the sturdy pin 90 downward, rotating the retractor lever 80 in a clockwise direction. This causes the transverse pin 128 to move against the cam surface 124 a , 124 b of the upward driver arm 122 and pivot the deadlocking arm 114 in a clockwise direction raising the arm 114 so that the notch 118 raises ( FIG. 5 ), moving the blocking surface 120 out of the path of the pin 130 thereby canceling the deadlocking action of the deadlocking arm 114 and allowing for subsequent retraction with the deadbolt 18 . Continued movement of the press bar causes the top of the leftward side of the retractor lever 80 to work under the lobe 30 a of the retractor blade 20 causing its counterclockwise rotation. As will be understood by now, the nose 40 works against the wall of the 38 of the insert 36 , part of the deadbolt 18 , to retract the deadbolt. Engagement of the front end surface of recess 54 in the underside of the retracting deadbolt with the foot 102 on the deadlocking plunger 100 , drives back the deadlocking plunger.

[0071] At all times during which pressure is put on the door with the deadbolt in its keeper, the bearing surface 42 of the retractor blade 20 bears against the surface 34 a of the floor of the cutout 34 and the pivot pin 28 . This provides an anti-friction means for overcoming what can be a very substantial bearing force working to displace the deadbolt inward as force is exerted inward by the keeper roller K.

[0072] Clearly, once the front of the deadbolt 18 clears the keeper roller K, the door is free to move open. When pressure is released from the press bar, the spring 136 drives the deadbolt outward and spring 144 drives the deadlocking plunger 100 outward. The lock returns to the condition described and as shown in FIGS. 2 and 4 .

[0073] Another embodiment of the present invention is shown in FIGS. 10 and 11 . In this embodiment, the arc 42 of the periphery of the blade portion 32 is formed with teeth 41 defining the arc segment of a gear. The surface 34 a of the longitudinal cut-out 34 is also formed with teeth which define a toothed rack. The teeth 41 , 34 a provide a connection for interrelated movement between the retractor blade 20 and the deadbolt 18 .

[0074] In operation, the retraction of the deadbolt 18 is driven by the retractor blade 20 as its lobe 30 a is raised by the linkages described above. As the teeth 41 of the retractor blade 20 progressively engage the teeth 34 a of the deadbolt, the pivoting retractor blade 20 drives the deadbolt toward the retracted position. Engagement of the teeth 41 , 34 a assures that the retractor blade will not extend when the deadbolt is retracted.

[0075] Similarly, when the door is closed the keeper roller K forces the retractor blade 20 in a counter-clockwise direction so that the teeth 41 , 34 a progressively engage and drive the deadbolt toward the retracted position. Engagement of the front end surface of recess 54 in the underside of the retracting deadbolt with the foot 102 on the plunger drives back the deadlocking plunger 100 . Once the deadbolt is past the keeper roller K, it snaps outward being driven out by spring 136 to lock the door.

[0076] Another embodiment of the present invention is shown in FIGS. 12 - 16 . In this embodiment, the deadbolt 18 is retracted by means of linkages between the press bar 14 and the deadbolt 18 . For this arrangement, a U-shaped deadbolt extension 165 is mounted on the rear end of the deadbolt 18 . Retractor links 151 , 152 are slidingly mounted in longitudinal slots 157 in each of the rearwardly extending legs of the deadbolt extension 165 using a link pin 158 . The rearward ends of the retractor links 151 , 152 are secured to a press bar lever 163 by means of a pivot pin 159 . The press bar lever 163 rotates on a pin 162 in a housing 164 which is mounted to the base plate 22 by screws 166 . A cross-pin 159 is fixed to depending sides of the press bar 14 and passes through an arcuate slot 168 in the housing 164 .

[0077] As seen in FIG. 13 , when the press bar 14 is depressed, the retractor lever 163 rotates in a counterclockwise direction. This draws the retractor links 151 , 152 rearward thereby retracting the deadbolt 18 . Engagement of the front end surface of recess 54 in the underside of the retracting deadbolt 18 with the foot 102 on the plunger 100 drives back the plunger. As described above, the retractor blade 20 is also drawn into retracted position since the retractor blade 20 and the deadbolt 18 are connected for interrelated movement by the engagement of the lug 72 with the front wall 36 c of the insert. Alternatively, it is understood that interrelated movement between the retractor blade 20 and the deadbolt 18 may be accomplished by forming the arc 42 of the periphery of the blade portion 32 and the surface 34 a of the longitudinal cut-out 34 with interengaging teeth.

[0078] The retractor blade 20 also functions as described above upon closing of the door to retract the deadbolt 18 . The slots 157 in the deadbolt extension 165 are long enough to allow the deadbolt 18 to move to the retracted position without the deadbolt extension 165 engaging the link pin 158 .

[0079] The deadlocking linkage pin 104 journals a yoke 156 which is of U-shape having forward legs 155 , 114 . The long, forwardly extending leg 114 forms a deadlocking arm for effecting deadlocking of the deadbolt 18 as in the previously described embodiments. The shorter leg 155 defines a deadlocking release arm. One of the retractor links 152 includes an extension 153 having a release actuator 154 positioned above leg 155 of the yoke 156 .

[0080] Upon the actuation of the press bar 14 , the retractor links 151 , 152 are drawn rearward causing the release actuator 154 to move against the leg 155 of the yoke 156 and pivot the deadlocking arm 114 in a clockwise direction raising the arm 114 . With the arm 114 raised, the blocking surface 120 is moved out of the path of the pin 130 thereby canceling the deadlocking action of the deadlocking arm 114 and allowing for subsequent retraction with the deadbolt 18 . Continued movement of the press bar draws the deadbolt 18 to the retracted position.

[0081] The provision of the retractor blade 20 and its bearing surface 42 make possible the use of a deadbolt in the present exit device. Repeating, the rolling surface 42 and pivot pin 28 effectively oppose the pressure ( FIG. 1 ) exerted by the keeper roller K tending to displace the deadbolt inward against adjacent structures. By means of the retractor blade with its bearing surface and pivot pin, the industry is finally able to have an exit device featuring a deadbolt as its securing means with the concomitant improvement in security. If desired or necessary, anti-friction coatings may be used on the deadbolt and other parts to reduce friction and make the operation even smoother.

[0082] Although the present invention has been described in considerable detail in connection with a preferred embodiment thereof, it will be understood, of course, that I do not intend to limit the invention to that embodiment since modifications may be made by those skilled in the art, particularly in light of the foregoing teachings. For example, an exit device having a deadbolt as its securing is effective where any type of activating means is employed for pivoting the retractor blade, including vertical door rod exit devices. On the contrary, I intend to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims. It is, therefore, contemplated by the appended claims to cover any such modifications as incorporating those features which constitute the essential features of these improvements within the true spirit and scope of the invention. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred embodiment contained herein.