Spindle assembly with captive spring for use in a door handle assembly

[0001] 1. Field of the Invention

[0002] The present invention relates to a door handle assembly, and, more particularly, to a spindle assembly with a captive spring for use in a door handle assembly.

[0003] 2. Description of the Related Art

[0004] Door handle assemblies have long been available that include a door handle, e.g., knob or lever, for operating a door latch mechanism. The door handle includes, for example, an operator portion and a shank. Included in the door handle assembly is a coupling, which may include two or more loose parts, that connects the door handle shank to the door latch mechanism.

[0005] Split-hub latches are used, wherein each hub portion of the split hub rotates independently of the other hub portion to operate the latch bolt of the door latch mechanism. In some designs, two separate spindles are used to independently operate each of the two hub portions, with each spindle being driven by a separate operator, e.g., door handle or lever. Such an arrangement, however, may be difficult to assemble due to the multiple loose parts.

[0006] The invention, in one exemplary embodiment, is directed to a door handle assembly, including a latch mechanism and a spindle assembly. The latch mechanism has a split hub. The split hub has a first hub portion and a second hub portion. Each of the first hub portion and the second hub portion is configured to independently operate the latch mechanism. The spindle assembly includes a first spindle and a second spindle. The first spindle has a shaft portion located between a first head portion and a first coupling end. The shaft portion has a first hub drive portion configured to engage the first hub portion when inserted into the split hub in a first direction. The second spindle has a second head portion, a second hub drive portion and a second coupling end. The second coupling end is configured to slidably engage the first coupling end of the first spindle to provide independent rotational engagement of the first spindle with the second spindle. The second hub drive portion is configured to engage the second hub portion when inserted into the split hub in the first direction. A retainer device is attached to the shaft portion of the first spindle. A spring is positioned captive between the first head portion of the first spindle and the retainer device attached to the shaft portion of the first spindle.

[0007] The invention, in another exemplary embodiment, is directed to a spindle assembly. The spindle assembly includes a first spindle, a second spindle, a retainer device and a spring. The first spindle has a shaft portion located between a first head portion and a first coupling end. The shaft portion has a first hub drive portion. A second spindle has a second head portion, a second hub drive portion and a second coupling end. The second coupling end is configured to slidably engage the first coupling end to provide independent rotational engagement of the first spindle with the second spindle. The retainer device is attached to the shaft portion of the first spindle. The spring is positioned captive between the first head portion of the first spindle and the retainer device attached to the shaft portion of the first spindle.

[0008] The invention, in another exemplary embodiment, is directed to a method of forming a spindle assembly for use with a latch mechanism. The method includes providing a first spindle having a shaft portion located between a first head portion and a first coupling end, the shaft portion having a hub drive portion; and positioning a spring captive between the first head portion of the first spindle and a retainer device attached to the shaft portion of the first spindle.

[0009] The invention, in another exemplary embodiment, is directed to a method of assembling a door handle assembly, the door handle assembly including a latch mechanism having a split hub, the split hub having a first hub portion and a second hub portion, each of the first hub portion and the second hub portion being configured to independently operate the latch mechanism; a first door handle having a first operator portion, and a first shank extending from the first operator portion, the first shank having a first cavity; and a second door handle having a second operator portion, and a second shank extending from the second operator portion, the second shank having a second cavity. The method includes providing a spindle assembly including a first spindle, a second spindle, a retainer device, and a spring positioned captive between a first head portion of the first spindle and the retainer device attached to a shaft portion of the first spindle; sliding a second head portion of the second spindle of the spindle assembly through the split hub; inserting the first head portion of the first spindle in the first cavity of the first shank of the first door handle; engaging the spring of the spindle assembly with the first shank of the first door handle to position a first hub drive portion of the first spindle relative to the first hub portion and to position a second hub drive portion of the second spindle relative to the second hub portion.

[0010] In one embodiment, for example, an advantage of the invention is the reduction in the number of loose parts needed to assemble the door handle assembly, thereby making assembly easier.

[0020] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate embodiments of the invention, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.

[0021] Referring now to the drawings, and more particularly to FIG. 1, there is shown a door 10 having mounted thereto a door handle assembly 12. Door handle assembly 12 includes a door handle 14, a door handle 16, a latch mechanism 18, and a spindle assembly 20 in accordance with the present invention. The invention is designed to adjust to a limited range of door thickness and manufacturing tolerances of the door handle assemblies and installations, while keeping spindle assembly 20 properly aligned in latch mechanism 18.

[0022] Door handle 14 has an operator portion 22 and a shank 24 extending from first operator portion 22. Door handle 14 may be, for example, an interior door handle. In the embodiment of FIG. 1, operator portion 22 is a door knob. Shank 24 has a cavity 26. Cavity 26 has a shape and depth selected to accommodate a corresponding portion of spindle assembly 20.

[0023] Door handle 16 has an operator portion 28, and a shank 30 extending from operator portion 28. Shank 30 has a cavity 32. Cavity 32 has a shape and depth selected to accommodate a corresponding portion of spindle assembly 20.

[0024] Latch mechanism 18 includes a body 34 supporting a latch bolt (not shown) operated by a split hub 36. Split hub 36 has a first hub portion 38 and a second hub portion 40. Each of first hub portion 38 and second hub portion 40 are configured to independently operate latch mechanism 18 by their respective individual rotation about a rotational axis 42.

[0025] As shown in FIGS. 2, 3 and 4, spindle assembly 20 includes a first spindle 44, a second spindle 46, a retainer device 48 and a spring 50.

[0026] First spindle 44 has a shaft portion 52 located between a head portion 54 and a coupling end 56. Shaft portion 52 has a first hub drive portion 58. First hub drive portion 58 is configured to engage first hub portion 38 of split hub 36 when inserted into split hub 36 in a direction 60 along rotational axis 42 (see also FIG. 1).

[0027] Head portion 54 of first spindle 44 has a size and shape corresponding to that of cavity 26 of shank 24 of door handle 14. Cavity 26 of door handle 14 is configured to slidably receive and drive head portion 54 of first spindle 44, so as to facilitate the common rotation of shank 24 and first spindle 44, and in turn first hub portion 38 of split hub 36, about the rotational axis 42 to operate latch mechanism 18 independently from the operation of latch mechanism 18 by door handle 16.

[0028] Referring to FIGS. 5A and 5B, shaft portion 52 and head portion 54 of first spindle 44 have common orthogonal dimensions 62 and 64, e.g., height and width, in cross-section, and have at least one different diagonal dimension in cross-section. For example, the diagonal dimension 66 of shaft portion 52 is smaller than the corresponding diagonal dimension 68 of head portion 54. The common orthogonal dimensions 62 and 64 define a generally rectangular structure, such as a generally square structure, in cross-section. In the embodiment shown, shaft portion 52 has reduced cross-section, e.g., beveled, corners 70a, 70b, 70c and 70d, thereby defining head portion 54 of first spindle 44 where reduced cross-section, e.g., beveled, corners 70a, 70b, 70c and 70d end. As shown in FIG. 5A, diametrically opposed beveled corners 70a and 70c are located at the diagonal dimension 66 of the rectangular structure. Beveled corners 70b and 70d are located diametrically opposed along another diagonal dimension.

[0029] Those skilled in the art will recognize that the reduced cross-section corners 70a, 70b, 70c and 70d may have shapes other than beveled in cross-section. For example, in addition to being beveled, reduced cross-section corners 70a, 70b, 70c and/or 70d may be rounded, or form a smaller square in cross-section than head portion 54.

[0030] Referring again to FIGS. 2-4, second spindle 46 has a head portion 72, a second hub drive portion 74, and a coupling end 76. Coupling end 76 is configured to slidably engage coupling end 56 of first spindle 44 to provide independent rotational engagement of first spindle 44 with second spindle 46. For example, coupling end 76 of second spindle 46 may be configured as a cylindrical bore, and coupling end 56 of first spindle 44 may be configured as a cylindrical piston. Second hub drive portion 74 is configured to engage second hub portion 40 of split hub 36 when inserted into split hub 36 in direction 60.

[0031] Head portion 72 of second spindle 46 has a size and shape corresponding to that of cavity 32 of shank 30 of door handle 16. Cavity 32 of door handle 16 is configured to slidably receive and drive second head portion 72 of second spindle 46, so as to facilitate the common rotation of shank 30 and second spindle 46, and in turn second hub portion 40 of split hub 36, about the rotational axis 42 to operate latch mechanism 18 independently from the operation of latch mechanism 18 by door handle 14.

[0032] Retainer device 48 is attached to shaft portion 52 of the first spindle 44. Shaft portion 52 may include, for example, a peripheral groove 78. As such, retainer device 48 may be in the form of a C-clip that engages peripheral groove 78.

[0033] Spring 50 may be, for example, a coil spring having a diameter sized to slide over shaft portion 52 of first spindle 44, but sized to not slide over head portion 54 of first spindle 44, as illustrated in FIGS. 3 and 5B. Thus, in the example shown, spring 50 is positioned around beveled corners 70a, 70b, 70c, 70d of shaft portion 52 of first spindle 44, and is retained captive between head portion 54 of first spindle 44 and retainer device 48, e.g., a C-clip, that is attached to shaft portion 52 of first spindle 44. As shown in FIG. 5B, the corners of head portion 54 serve to restrain spring 50 on first spindle 44, while the flats 80a, 80b, 80c, and 80d of first spindle 44 serve to expose portions of spring 50 for engagement with shank 24 of door handle 14 when spindle assembly 20 is installed in door handle assembly 12.

[0034] Thus, referring also to FIG. 1, when spindle assembly 20 is connected to door handle 14, spring 50 engages a portion of shank 24 to bias spindle assembly 20 with respect to latch mechanism 18 in direction 60. More particularly, spring 50 engages shank 24 to position first hub drive portion 58 of first spindle 44 relative to first hub portion 38, and to position the second hub drive portion 74 of second spindle 46 relative to second hub portion 40. In the example shown in FIG. 1, for example, spring 50 forces retainer device 48 of the spindle assembly 20 in direction 60 until retainer device 48 engages latch mechanism 18.

[0035] FIG. 6 is a general flowchart for making and assembling spindle assembly 20 for use, for example, with latch mechanism 18, as shown in FIG. 1.

[0036] At step S100, first spindle 44 is provided having shaft portion 52 located between head portion 54 and first coupling end 56. Shaft portion 52 and head portion 54 of first spindle 44 may be formed, for example, to have common orthogonal dimensions 62, 64 (see FIG. 5A) and to have at least one different diagonal dimension, e.g., diagonal dimension 66 of shaft portion 52 is smaller than diagonal dimension 68 of head portion 54. Peripheral groove 78 may be formed in shaft portion 52 at a location spaced from head portion 54 of first spindle 44 to receive retainer device 48, such as for example, a C-clip.

[0037] At step S102, spring 50 is positioned to be captive between head portion 54 of first spindle 44 and retainer device 48.

[0038] At step S104, retainer device 48 is attached to shaft portion 52 of the first spindle 44.

[0039] At step S106, coupling end 56 of first spindle 44 is slidably engaged with a coupling end 76 of second spindle 46.

[0040] At step S108, coupling end 76 of second spindle 46 is attached to coupling end 56 of first spindle 44, such as for example, by staking or crimping the end of coupling end 76 so that coupling end 56 is retained in coupling end 76. Thus, first spindle 44 and second spindle 46 are permanently joined, but remain independently rotatable with respect to each other about rotational axis 42. Once attached, the assembly of spindle assembly 20 is complete, and spring 50 can not be removed from spindle assembly 20 without destructive effort.

[0041] FIG. 7 is a general flowchart of a method of assembling door handle assembly 12 of FIG. 1.

[0042] At step S200, spindle assembly 20 is provided in an assembled state, as discussed above.

[0043] At step S202, head portion 72 of the second spindle 46 of spindle assembly 20 is slid through split hub 36.

[0044] At step S204, after head portion 72 of the spindle assembly 20 passes through split hub 36, head portion 72 is received in cavity 32 of shank 30 of door handle 16. Door handle 16 may have been, for example, previously attached to door 10.

[0045] At step S206, head portion 54 of first spindle 44 is inserted in cavity 26 of shank 24 of door handle 14, such as for example, as door handle 14 is being mounted to door 10.

[0046] At step S208, spring 50 of the spindle assembly 20 engages shank 24 of door handle 14 to position first hub drive portion 58 of first spindle 44 relative to first hub portion 38 of split hub 36 of latch mechanism 18, and to position second hub drive portion 74 of second spindle 46 relative to second hub portion 40 of split hub 36 of latch mechanism 18. The engagement of spring 50 with shank 24 of door handle 14 may occur, for example, as door handle 14 is being mounted to door 10. The engagement of spring 50 with shank 24 of door handle 14 may be, for example, at an external end of shank 24, or may be at an interior ledge in cavity 26 in shank 24 of door handle 14.

[0047] While this invention has been described with respect to embodiments of the invention, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.