Title:

Improvements in Members <£. XponirrrøO ^ ^ ^" M

Background and Unresolved Needs: Many types of articles have previously been fabricated as solid objects. However, rapidly rising materia! costs make it desirable to manufacture articles that appear and feel the same (as those manufactures as solid objects) but which employ less material; the inventions within amongst other things, address this issue by providing a particular hollow construction. The inventions within are particularly relevant to cast articles that include pressure zinc die castings and plastic injection mouldings.

The inventions within (although not limited to) find application in ironmongery and handles in particular and they also find application in lock cylinders.

The inventions within also address common deficiencies found in plastic handles sets. It should be understood that the inventions within are not limited to the applications described above.

Summary of the Inventions

According to one aspect of the invention, there is a member including a first portion assembled to a second portion, said first portion having at least one sloping surface disposed relative to an adjacent fixing shoulder, said second portion having a fixing pin for each fixing shoulder disposed relative to the sloping surface 12, said fixing pin in the assembled member overlapping both the sloping surface and the fixing shoulder 13 to restrain the portions against separation. In a second aspect of the invention, the at least one fixing pin is defined in part by a longitudinal axis that during assembly intersects the sloping surface and after assembly extends sideways to overlap the fixing shoulder.

In a third aspect of the invention, the at feast one fixing pin includes a leading end having a substantially rectangular cross-section characterized by having a lesser width in the direction of sideways extension than the orthogonal width.

In a fourth aspect of the invention, the sloping surface and fixing shoulder ar& disposed relative to a fixing recess in the first portion.

In a fifth aspect of the invention, either or both the first and second portions are configured as a single casting.

In a sixth aspect of the invention, either or both of the first and second portions are configured as a single zinc diecast member wherein each fixing pin is configured to be able to plastically deform.

In a seventh aspect of the invention, there is a member configured as a barrel for a cylinder lock, wherein the first portion is configured as a substantially cylindrical plug while the second portion is configured as a substantially disc-like head, said plug and head attached by at least one fixing pin that protrudes from the head to overlap a fixing shoulder of the plug to restrain the plug and head against separation. In an eighth aspect of the invention, the plug includes at least one fixing recess extending from a first end of the plug to adjoin a side recess bounded in part by a sloping surface.

In a ninth aspect of the invention, the plug includes a pair of fixing recesses disposed relative to a pair of opposed side recesses that extend inwardly from the surface of the plug towards each other, each said fixing recess extending past its associated side recess and having a profiled outer side configured to provide a substantially uninterrupted connection between the fixing recess and its associated side recess, each said fixing recess adjacent to the associated side recess including an outwardly sloping surface In a tenth aspect of the invention, the barrel includes a longitudinally extended key recess that extends within the plug and head and that includes at least one sideways protruding fin extending from a side wall, said plug including multiple pin channels intersected by both the key recess a cross channel that extends from the surface of the plug between adjacent pin channels. In an eleventh aspect of the invention, the plug includes a bridge at each end connecting two plug halves together.

In a twelvth aspect of the invention, the barrel has either or both the head and plug further configured by electroplating or other means to have different surface coatings.

According to another aspect of the invention, there is a barrel for a cylinder lock having a first portion configured as a substantially cylindrical plug and a second portion configured as a substantially disc-like head, said barrel including a longitudinally extended key recess that extends within the plug and head and that includes at least one sideways protruding fin extending from a side wall, said plug including multiple pin channels intersected by both the key recess a cross channel that extends from the surface of the plug between adjacent pin channels.

In fourteenth aspect of the invention, the side walls of the cross recess lie within spaced substantially parallel planes that in part define the side walls of the key recess. In a fifteenth aspect of the invention, there is a handle having a second portion configured as a handle body including a hollow portion from which at least one fixing pin extends and a first portion comprising a cover plate that extends to cover the hollow and having a fixing shoulder and sloping surface.

In a sixteenth aspect of the invention, the handle body includes a pair of spaced fixing pins and the cover plate includes a pair of corresponding fixing recesses and sloping surfaces and fixing shoulders. In a seventeenth aspect of the invention, each sloping surface is within an aperture that extends from an opening in the surface of the cover plate.

In an eighteenth aspect of the invention, the handle is within a handle assembly including a base, said base having a coplanar underside for mounting against a wing, said handle hollow portion characterized by an opening disposed towards the underside of the base, said handle base further characterized by the longitudinal axis of each fixing pin being substantially orthogonally disposed to the underside of the base.

In a nineteenth aspect of the invention, the handle base and cover plate are each configured as a single zinc die castings wherein each fixing pin is configured to be able to plastically deform. According to another aspect of the invention, there is a handle substantially as described herein with reference to and as illustrated in the accompanying drawings.

According to another aspect of the invention, there is a handle assembly substantially as described herein with reference to and as illustrated in the accompanying drawings. According to another aspect of the invention, there is a barrel substantially as described herein with reference to and as illustrated in the accompanying drawings.

According to another aspect of the invention, there is a method of manufacturing a member including a first portion assembled to a second portion wherein said first portion has at least one sloping surface 12 disposed relative to an adjacent fixing shoulder and said second portion 7 has a fixing pin 6 for each fixing shoulder by: aligning each fixing pin relative to its associated sloping surface and fixing shoulder, and displacing the portions axially towards each other to cause the fixing pins to displace along the sloping surfaces to be plastically deformed to displace sideways to overlap the fixing shoulder to effect a connection between the two portions.

In a twenty fourth aspect of the invention, there is a method of manufacturing a barrel, wherein the barrel includes a head having at least one fixing pin and a plug having a fixing recess and a sloping surface and a fixing shoulder for each fixing pin by: aligning each fixing pin relative to its associated sloping surface and fixing shoulder, and displacing the head and plug axially towards each other to cause the fixing pins to displace along the sloping surfaces to be plastically deformed to displace sideways to overlap the fixing shoulder of the plug to effect a connection.

In a twenty-frfth aspect of the invention, there is a method of manufacturing a handle, wherein the handle includes a handle body having at least one fixing pin and a cover plate having a fixing recess and a sloping surface and a fixing shoulder for each fixing pin by: aligning each fixing pin relative to its associated sloping surface and fixing shoulder, and displacing the handle body and cover plate axially towards each other to cause the fixing pins to displace along the sloping surfaces to be plastically deformed to displace sideways to overlap the fixing shoulder of the plug to effect a connection.

In a twenty sixth aspect of the invention, there is a method of manufacturing a barrel, including depositing material into a plug cavity in a closed die to form the plug; said die characterized by: die halves that are retractabfe with respect to the centre-line of the barrel and having cores positioned substantially diametrically opposite one another and extending into the barrel cavity so as to abut or be in close proximity to one another when the die is closed, one core comprising a central web about which a plurality of pairs of opposed protrusions extend and about which material is deposited to form guide channels for pins, another core in conjunction with the aforementioned core forming a keyway to receive a key, and an axial inwardly projecting longitudinal recess formed at the junction between the cores into which material is deposited to form a longitudinal fin.

In a twenty seventh aspect of the invention, there is a method of manufacturing a barrel, including depositing material into a plug cavity in a closed die to form the plug, said die characterized by: a sliding core retractable axially with respect to the centre-line of the barrel and characterized by at least one pin portion that extends into the plug cavity when the die is closed and about which material in deposited to form a fixing recess and the sloping surface,

the inner end of said pin portion in the dosed die, overlapping and abutting a side shoulder of the die to form a substantially uninterrupted connection between the side recess and pin recess.

In a twenty eighth aspect of the invention, there is a method of manufacturing a barrel, including depositing material into a head cavrty in a closed die; said head die characterized by: die halves that are retractable with respect to the axis of the head and having cores positioned substantially diametrically opposite one another and extending into the head cavity so as to abut or be in close proximity to one another when the die is closed, each core comprising a central web about which material is deposited to form the keyway, one die half having at least one axial profiled recess into which material is deposited to form a fixing pin.

In a twenty ninth aspect of the invention, there is a method of manufacturing a handle, including depositing material into a cover plate cavity in a closed die; said die characterized by: die halves that are retractable with respect to the centre-line of the cover plate and having cores positioned substantially diametrically opposite one another and extending into the cavity so as to abut or be in close proximity to one another when the die is closed, one core including an angled surface the other including orthogonal surface about which material is deposited to respectively form the sloping surface and fixing shoulder.

In a thirtieth aspect of the invention, there is a method of manufacturing a handle, including depositing material into a handle body cavrty in a closed die; said die characterized by: die halves that are retractable with respect to the centre-line of the handle body and in one die half having a raised portion to form the hollow within which a recess extends and into which material is deposited to form a fixing pin.

According to another aspect of the invention, there is a method of manufacture substantially as described herein with reference to and as illustrated in the accompanying drawings. According to another aspect of the invention, there is a method of manufacturing a barrel Substantially as described herein with reference to and as illustrated in the accompanying drawings.

According to another aspect of the invention, there is a method of manufacturing a handle substantially as described herein with reference to and as illustrated in the accompanying drawings.

The elements relating to the various aspects of the invention claimed within are identified within the specification as follows: where unless the context requires otherwise,

• "Locks" or variations such as "lock" will be understood to include complete locks for wings and improvements in locks for wings that are transportable into other locks and locking devices without being limited to the complete locks described herein.

• "Comprise" or variations such as "comprises" or "comprising" will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers. • Positional prepositions such as "rear" and "forward" are used to assist in description of the preferred embodiments and with reference to the accompanying drawings and have in general, no absolute significance

• "Overlap" and derivations such as "overlaps" implies at least in-part, occupying a same plane as. • "Extent" will be understood to include area, form and shape

• Headings are included for convenience only and not to affect on interpretation.

• "Preferably" or variations such as "prefer" does not impJy that the form of an integer is restricted to that referred to as preferred, but implies acceptable and if need be, able to adequately perform a function required by the inventions in which it is included.

• "Wing" or variations such as "wings" will be understood to include complete wings and improvements in wings that are transportable into other devices without being limited to the complete wings described herein; wings embraces in particular "doors', "windows", "shutters" and "screens".

• "Member" is an identifiable entity having material form that may include one or more identifiable components.

• "Material" includes elements, alloys, plastics and other substances.

• "Aperture" and "recess" embrace a hole that extends from a surface while "aperture" in some contexts implies a hole that extends between surfaces.

• "Furniture" includes door furniture that includes a "Handle Assembly" that includes a handle.supported by a base that together in one form comprise an unlatching lever supported by a back-plate; "Handle" includes a knob, lever and an unlatching lever; "Unlatching Lever" includes a lever or knob that is hand operable to cause an engaging member to become unlatched": "Base" includes a rose that may

include a surface mounted member having a recess on the underside: "Back-Plate" (or "back-plate") includes a surface mounted box-like member having a recess on the underside.

• "Engaging Member" in isolated use, is a member displaceabie between a fully displaced disposition and a fully retracted disposition When employed with an

"Engageable Member", the engaging member is displaceabie between an operative disposition (in which the engaging member finds itself when engaged with the engageable member) and an inoperative disposition removed from the said engagement. Within this specification, fully displaced will embrace the operative disposition and retracted disposition will embrace the inoperative disposition.

• "Latching" implies displacement of an "engaging member into engagement with an "engageable member" under the action of biasing means.

• "Latch-Bolt" or "latch bolt" is an outwardly biased bott capable of executing

(or participating in) latching and includes bolts having a leading end that is chamfered or otherwise profiled on one or both sides.

• "Auxiliary bolt" is a plunger that is operably associated with a latch bolt.

• "Unlatching" means withdrawal of the engaging member, from engagement.

• "Locking" means the act of configuring the lock to restrain it from being unlatched and in some forms of locks employing deadlocking slides, it means restraining the deadlocking slide to restrain the bolt from being inwardly displaced in response to operation of the unlatching lever.

• Trench Door" means a door including a frame and a glass in-fill.

• "Screen door" means a door including a frame and an insect restraining in-fill such as fiberglass mesh, woven mesh or perforated metal mesh; and a conventional security door is defined by fitting within an industry-standard door preparation and having a lock casing having dimensions Depth 35 to 45 MM. Width 14.5 to 16 MM and length 147 + or - 4 MM

• "Lock Body" includes an engaging member and a lock casing.

• "Mortise Lock" means a lock including a lock body, a strike plate, a pair of handle assemblies and a cylinder where the lock body is configured to be fitted within the frame of the wing. ^•

• 'Single cylinder" means a substantially conventional lock cylinder comprising a separate sub-assembly that includes a key operable barrel within a cylinder housing ♦ "Double-Cylinder" comprises a substantially conventional double lock

cylinder comprising a separate sub-assembly that includes opposed coaxially supported barrels each operably connected to the same angularly displaceable "first cam" having a 'first cam arm" characterized by a "free end" that extends radially to a "peripheral surface" defined in part by a common radial distance from the first cam pivotal axis and where in a conventional double cylinder this radial distance is 15.0

MM.

• A "mortise joint" includes two elongated members have ends that abut along an entire angled edge and in this configuration the angle at which the axis of the members are disposed to each other is said to be the "nominal angle"; • An Orthogonal mortise joint" has orthogonally disposed members having a nominal angle of 90 degrees and abutting ends each angled at 45 degrees,

• A "pseudo mortise joint" is a mortise joint where the two elongated members are relatively disposed at an angle ["deviation"] slightly different from the nominal angle so that their ends abut at a corner only to have a wedge like gap between them an a "pseudo orthogonal mortise joint" has members having abutting ends angled at 45 degrees that abut only at a corner.

• A "butt joint" is a joint characterized by two elongated hollow members relatively disposed at an included angle to each other where an end of a first member (disposed at a nominal angle to its longitudinal axis) abuts a side of a second member along the entire periphery of the end and where the included angle is equal to the nominal angle.

• An Orthogonal butt joint" is a joint characterized by the two elongated hollow members being relatively disposed at an angle 90 degrees.

• A "pseudo butt joint" is a joint characterized by the included angle being slightly different to the nominal angle and the first member abuts a side of a second member at a corner and a "pseudo orthogonal butt joint" is a joint characterized by two elongated hollow members being disposed at an angle different from 90 degrees by the "deviation".

• "Deviation" is an incremental angle = nominal angle - included angle • "Cross-Sectional View ^* in relation to figures should be interpreted as an orthogonal cross-sectional view defined by a plain orthogonal to the axis of the member in consideration.

Patent Specification shall be taken to include: a Body [comprising a Title, a Description of Preferred Embodiment/s, an Abstract and a Summary of the Invention] and Claims.

Unless the context requires otherwise, any prior publications and usage referred to herein, is not an assertion that any of this material forms part of the common general knowledge in the art in any other country at the priority date of any daim herein (or the priority date of any future claimed derived at least in part from this specification). The inventions described within derive, at least in part, from those described in associated provisional applications and where unless the context requires otherwise, where an integer is attributed with attributes different from those attributed, in an earlier provisional application, the integer wHi be considered to be the same integer in a different form; where there is actual inconsistency between a provisional application and an earlier provisional application, the latter will prevail.

The integers described within relate to a) the various aspects of the invention as claimed within, and b) the various aspects of other inventions as claimed in derived divisional applications.

Brief Description of the Drawings

Notwithstanding any other forms that may fall within its scope one preferred form of the invention will now be described by way of example only with reference to the accompanying drawings in which:

Figure 1 is an isometric view of a member, Figure 2 is cross sectional view of the member of Fig 1 defined by a plane occupied by the axis of the member and intersecting the fixing pins. Figure 3 is an enlarged view of portion of the handle of Fig 2 Figure 4 is an enlarged view of an alternative portion of the handle of Fig 2 Figure 5 is a schematic view of the tooling employed to manufacture the fixing recess corresponding to the members of Fig 3 and 4 and includes a cross-section through the portion of the die that forms the fixing recess.

Figure 6 is a cross sectional view of an alternative assembled handle defined by a plane orthogonal to the longitudinal axis of the member and intersecting the fixing pin and the associated tooling. Figure 7 is a schematic view of the tooling employed to manufacture the fixing pins corresponding to the member of Fig 3 and 4 and includes a cross-section through the portion of the die that forms the fixing pins.

Figure 8 is an isometric exploded view (viewed from the underside) of a handle assembly.

Figure 9 is the handle assembly of Fig 8 viewed from the outer side, Figure 10 is cross sectional view/ AA of Fig 8 (uπ-exploded) defined by a plane occupied by the handle pivotal axis and the longitudinal axis of the base,

Figure 1 1 is cross sectional view BB of Fig 8 (un-exploded) defined by a plane occupied by the handle pivotal axis and orthogonal to the longitudinal axis of the base, Figure 12 is cross sectional view CC of Fig 8 (un-e>cploded) defined by a plane occupied by the axis of the lower fixing boss and the longitudinal axis of the base,

Figure 13 is an exploded isometric view of a barrel for a pin cylinder lock showing the head separated from the plug, Figure 14 is end view of the barrel,

Figure 15 is cross-sectional view AA referencing Fig 15, Figure 16 is cross-sectional view BB referencing Fig 16, Figure 17 is cross-sectional view CC referencing Fig 17, Figure 18 is cross-sectional view DD referencing Fig 4 Figure 19 is a plan view of a portion of the die, in which the first cavity resides,

Figure 20 is cross-sectional view FF referencing Fig 7, Figure 21 is cross-sectional view GG referencing Fig 7, Figure 22 is cross-sectional view GG referencing Fig 7, Figure 23 is an isometric view of the moving half of the first cavity, Figure 24 is an isometric view of the fixed half of the first cavity,

Figure 25 is as isometric view from the rear of the plug Figure 26 is a plan view of the plug

Figure 27 is a plan view of plugs within the moving half of the die. Figure 28 is cross-sectional view EE referencing Fig 15 Figure 29 is a portion of a die that includes a second cavity.

Figure 30 is cross-sectional view CC referencing Fig 17 Figure 31 is cross-sectional view DD referencing Fig 17 Figure 32 is an isometric view of the moving half of the second cavity, Figure 33 is an isometric view of the fixed half of the second cavity.

Detailed Description of Embodiments consistent with the Concepts of the Inventions

Some members include at least first portion 1 assembled to a second portion 7, (Fig 1 to 4) said first portion 1 having at ieast one sloping surface 12 disposed relative to an adjacent fixing shoulder 13, said second portion 7 having a fixing pin 6 for each fixing shoulder disposed relative to the sloping face 12, said fixing pin in the assembled member overlapping both the fixing shoulder 13 and sloping surface 12 to restrain the portions against separation. In more particular forms, the at least one fixing pin includes a leading end defined in part by a longitudinal axis that after assembly extends sideways to overlap the fixing shoulder and that before assembly intersects the sloping surface.

In some forms, both the first and second portions are each configured as a single casting and in some forms, each comprises a single zinc diecast member capable of limited plastic deformation. In some forms, each portion is defined in-part at least, relative to a plane (that may be profiled) that defines the junction between the two portions. During assembly, the first portion 1 and second portion 7 are attached to each other by aligning each fixing pin 6 relative to its associated sloping surface 12 and fixing shoulder 13 and displacing the portions axially towards each other (by the application of a force) to cause the fixing pin to displace along the sloping surfaces 12 to be plastically deformed to displace sideways to overlap the fixing shoulder 13 to effect a (concealed or substantially concealed depending on the form being considered) connection between the two portions.

In some forms, the first portion is further configured to include an elongated fixing recess 2 that extends inwardly from an opening 9 to an aperture 11 that (at least in part) overlaps the sloping surface 12 and the fixing shoulder 13 comprises a portion of the first member disposed relative to the sloping surface 12. The portions are configured such that during assembly when the fixing pin is advanced axially into the fixing recess, the walls of the fixing recess 2 act to restrain the fixing pin from displacing sideways as the protruding portion of the fixing pin 6 is displaced sideways by the sloping surfaces 12 In a particular form, the fixing shoulder is within a surface disposed orthogonally to the fixing recess and through which the aperture 11 extends.

In a particular form, each fixing pin 6 is configured as a trailing portion 8 having one end connected to the body of the second portion and the opposite end configured as a leading end 10 having a smaller width in the direction it will be deflected - it will be appreciated that such a leading end 10 can be deformed at lower forces and with less likelihood of fracture. The fixing recess is correspondingly configured to have a portion 4 of reduced cross-section towards an inner end 5, portion 4 extending to the aperture 11

such that during assembly, each fixing pin 6 has passage through an opening 9 with not more than a small working clearance and the leading end 10 has passage with minimal clearance through the portion 4 and aperture 11 ; the portion 4 acting to restrain the leading end 10 from displacing sideways as the protruding portion of the leading end 10 is displaced sideways by the sloping surfaces 12 to create a plastically deformed fixing pin. In a particular form, the trailing portion 8 of the fixing pin is substantially square In cross- section while the leading end 10 is generally rectangular in cross section having a reduced width d2 in the direction the leading end is deflected; i.e. where d2 < d1.

In some forms, the end of the leading end 10 is profiled so that in the assembled member, the opening 14 is substantially occupied by he leading end 10 as shown in Fig 4. In some forms, the sloping surface 12 comprises an angled planar surface (Fig 3) while in other forms, it comprises a profiled surface that becomes more inclined (relative to the axis of the fixing pin) as it extends away from the fixing shoulder 13; in other forms it comprises a generally angled profiled surface; in a particular form, the sloping surface 12 is inclined at an angle substantially 30 degrees to the axis of the fixing pin.

In some forms, the sloping surface 12 is closely disposed relative to the fixing shoulder 13 to cause the sideways deflected pin portion to wrap closely round the fixing shoulder 13 to form a strong connection (Fig 4 and 3) between the portions; in other forms, the sloping surface 12 is disposed further from the fixing shoulder 13 and the fixing pin is deformed as a would be a cantilever beam.

To remove the first portion from the second portion requires each leading end 10 to be drawn through the aperture 11 by the application of a force. The force required to withdraw the fixing pin may be significantly larger than the force to insert the fixing pin because the already deformed portion of the leading end needs to be drawn across the fixing shoulder 13 that may comprise an end wall of the aperture 11 configured as a relatively sharp corner.

The first and second portions may be manufactured by any appropriate means and the fixing pins comprise separate members attached to the first portion by any appropriate means including having a threaded portion that extends into a threaded recess of the first portion.

However, in a more efegaπt manufacturing process, the first portion 1 is formed by injecting metal into a cavity with die parts Part C and Part D (Fig 5) tnat together provide a closed cavity having the form of the first portion 1 ; the second portion 7 is formed by injecting metal into a profiled cavity 20 with die parts Part A and Part B (Fig 7) that together provide a closed cavity having the form of the first portion 7. When the metal

freezes the die parts are separated and the portions are removed; all this is somewhat common conventional practice. in a particular form of this practice, the fixing recess 2 is manufactured by injecting metal around a profiled Pin C1 that abuts a profiled Pin D1; C1 being supported in Part C and extending into the cavity; Pin D1 being supported in Part D and extending into the second cavity, Pins C1 and D1 together taking the form of the fixing recess 2 to preclude metal being injected into this space. Referring to Fig 5, one sees that Pin C1 extends through the wall of the first portion 1 leaving an aperture 14 in the final casting. In an alternative method of manufacture (Fig 6) an alternative fixing recess 15 is manufactured by injecting metal around a profiled Pin D2 that abuts a profiled Pin D3, Pins D2 and D3 together taking the form of the fixing recess 15 to preclude metal being injected into this space; D2 being supported in Part D and extending into.the cavity; D3 being supported relative to Part D to extend orthogonally into the cavity and in some forms to be included in a substantially conventional orthogonal sliding side core that is displaced sideways withdrawn the Pin D3 from the cavity before the first portion 1 is removed from the cavity. Reference to Fig 6, shows that Pin D3 extends through a side of the boss 16 (within which the fixing recess 2 is formed) and in so doing, leaves an aperture 17 in the final casting that is not visible in the assembled member.

Although the casting practices described above are somewhat well known, the application of such technology to the manufacture of hollow cast handles is novel and requires a inventive.

In some members, the first portion 1 comprises a single casting that includes one ore more sets of sloping surfaces 12 and shoulders 13 and in some forms, the second portion 7 comprises a single casting that includes one ore more fixing pins 6 configured to be compatible with their associated fixing recess 2.

The handle described above may be further configured as a handle 21 within a handle assembly (Fig 8 to 12) and may be configured as an operable unlatching lever 22 that is supported by a block 23 that itself is supported within a recess 24- in the underside of a base 25 that may take the form of a back-plate 26; in some forms, the handle is hollow to reduce material content and has the construction described above. In some forms, the handle 21 and block 23 are within a separate sprung handle sub- assembly 27 that further includes a compression spring 28, a driver 29 and a threaded fastener 31 that extends freely through an aperture 51 in the driver to engage by way of threads within the aperture S2 within the unlatching member 22 to cooperate in attaching the unlatching member 22 to the block 23.

In some forms, the block 23, compression spring 28 and driver 29 are configured as a separate springing sub-assembly 30 that is attached tα the handle by means including the threaded fastener 31 ; the side walls of the spring recess 35 having adjacent spaced slots to form therebetween a displaceable resilient finger 40 having an inwardly extending shoulder 41 that overlaps the disc portion 53 and this has a leading end 44, characterized by and angled edge 45 (Fig 10) so configured that as the driver 29 is assembled to the block 23 [by axially displacing a substantially conical or cylindrical portion 4G of the driver through the axiat aperture 47 of the block 23] the edge 48 of the portion 53 is brought into contact with the angled edge 45 to displace it outwardly as ft slides up the angled edge 48 till an underside recess 49 of the finger 40 becomes adjacent to the edge 48, at which configuration the finger 40 displaces over the edge 46 to retain the driver 29 connected to the block 23. In other forms, a cast metal finger 40 is outwardly deformed by the angled edge to subsequently be inwardly deformed by hand tool. The springing sub-assembly 30 in the assembled handle assembly acts on the unlatching lever 22 to bias it against displacement from an undisplaced disposition, as a result of the spring 28 and block cooperating to bias the driver 9 against displacement from a corresponding undisplaced disposition.

In some forms of the inventions, the driver is free to rotate against biasing derived from spring 28 in one direction but restrained against biasing in the opposite direction by an inwardly extending shoulder 32 of the driver 29 that extends from a disc-like portion 53 of the diver to overlap-end wall 34 of a peripheral spring recess 35 (the shoulder 32 being within the spring recess 35 of the between the first end 33 and the end wall 34. The other end 37 of the spring 28 is configured to abut the other end wall 36 of the spring recess 35 to be held compressed between this and shoulder 22 whereby to bias the driver against displacement; the locus of movement of the shoulder 32 being defined by substantially circular axii orthogonal to the pivotal axis of the driver and unlatching member 22. The driver 29 includes an axially elongated shaft recess 39 that extends from the disc-like portion 53 to receive and mate with a shaft 64 that may be rectangular in cross-section as shown in the figures; the shaft extending to mate with a lock body.

During assembly, the spring is inserted in the spring recess so that end 37 abuts spring recess end 36 while the other end 33 extends across the shoulder between the end 34 and 36 The drive is assembled so the shoulder 32 abuts spring end 33. The driver is then turned till the shoulder 32 is adjacent to the spring recess at which configuration, the driver is displaced axiafiy into the spring recess 35 during which displacement, the fingers 40 engage the peripheral edge of the disc-like portion 53 of the

drive to retain the block 23, the driver 29 and the spring 28 assembled together as a separate sub-assembly

The block 23 is supported within the block recess 24 bounded by an upper wall 56 and a lower wall 57 (in the hollow underside of the base) that abut the block 23; the base 25 further including a handle aperture 58 that extends from the block recess 24 to the outer surface of the base through which the handle is connected to the driver 29. In some forms, the handle includes a hand operable portion 60 connected to a substantially cylindrical boss 59 that extends through handle aperture 57 that is connected to the driver 29. The handle is attached to the driver 29 so that they are displaceable together as one. In preferred forms, the boss includes a substantially conical recess 61 that mates with (a portion 46 configured as) a conical extension 62 of the driver similarly as does a Morse Taper joint; the conical recess 61 being further configured to include inwardly extending spline-like shoulder 63 that mate within outwardly extending spline-like shoulders 64 of the conical extension 62. Extending axially from the internal end of the shaft aperture 39 is an aperture 65 through which the screw 31 extends to engage by means of threads in a coaxial aperture 67 within the boss 59. In some forms, the conical extension 62 is effectively hollow (Fig 10 and 11) and includes a substantially conical recess 66 into which a mating portion of the boss 59 extends and this includes the aperture 67; this construction providing an elongated aperture 67 to provide enhanced thread engagement.

The inventions within, in some forms, include a pair of handle assemblies including an exterior handle assembly that includes an exterior lever and an exterior back- plate having an upper fixing sleeve 70 and a lower fixing sleeve 71 respectively each having a longitudinal fixing aperture 72 with which the shank (threaded portion) of the fixing screws engages in threaded engagement - the screws in application extending from an interior base relative to which the screw heads are retained to extend through a wing to engage in the fixing apertures whereby to retain the bases attached to the wing. In some forms, the interior base includes an upper and a lower fixing sleeve through with which the shank of the fixing screw has free passage.

In particular forms, the fixing sleeves comprise a substantially hollow cylindrical members 76 having outwardly protruding longitudinally elongated spline-like fins 77 that extend from beneath a substantially cylindrical head 78. Each fixing sleeve is supported in a substantially cylindrical recess 79 of the associated base having longitudinally elongated inwardly extending peripheral slots to receive and mate with the fins 77 to preclude relative angular displacement. The sleeve recess adjacent to the outer surface

of the base, is connected to a substantially cylindrical head recess 80 of greater diameter in which the head 78 is received. The head recess 80 i$ preferably further configured to receive a plug 81 that is inserted to hide the fixing sleeve.

Where the base comprises a back-plate 26, each sleeve recess is preferably within a substantially cylindrical extension 82 of the base from which fins 83 extend sideways to connect to side-walls of the base and which extend to the outer extent of the hollow portion so that when the back-plate is mounted to a wing, the fins 83 abut the surface of the wing to better support the extensions 82 and hence fixing sleeves. The fixing sleeves described above are particularly applicable to handles assemblies having a πoπ metallic base 25 (of plastic, wood or some other material) where the fixing sleeves are manufactured from metal to ensure adequate screw engagement; and in forms comprising single zinc castings manufactured by conventional means. In these forms, the driver may similarly comprise a metal component that in some forms comprises a single zinc casting manufactured by conventional means. It should be stated that the novel handle assembly described above is not limited to having hollow handles as described above, and the handles within may have any suitable construction.

This invention within also find application in the manufacture of pin cylinders which have usually been manufactured by machining the barrel from a brass blank by turning, broaching the keyway, drilling the guide channels (for the pins) to intersect the keyway so that the teeth of the key can move the pins to free the barrel for rotation within the cylinder housing. The barrel would also be machined to have an axial channel to receive the key into the barrel of the lock.

Barrels having wafers (instead of pins) are commonly cast; they generally have an un-plated plug and a separate stainless steel cap attached to the face to improve the appearance and a simplistic keyway. This construction is inappropriate for pin cylinders.

The inventions include a barrel 101 for a pin cylinder lock that includes a head 102 attached to a substantially cylindrical plug 103 as described below and as shown in Fig 13. The plug 103 has a generally cylindrical barrel configuration having a front face 104 incorporating an aperture 105 configured to receive a key (not shown) and a rear face 106 from which a drive means extends such as a spigot 107 shown in Fig 13, to connect the barrel to a further lock mechanism.

By one process, the plug 103 is formed within a substantially conventional cavity 108 within a portion of die 109 that includes a fixed recess 110 within a fixed half 111 and a moving recess 112 in a moving half 113; these being terms commonly used in the casting trade) to have the configuration shown in Fig 19 to 27. By one process the

head is formed in a cavity 115 within a portion of die 109 that includes a fixed recess 116 in the fixed half 111 and a moving recess 117 m the moving half 113 as described below.

The cavity 108 includes an orthogonal fixed core 120 that extends (orthogonally with respect to the axis of the barrel) from the fixed recess 110 and an orthogonal moving core 121 extends from within the moving recess 112 such that their leading edges 122 and 123 respectively abut when the halves of the die abut (when the die is closed) and in which configuration the cavities 110 and 112 combine to form the closed first cavity 108 into which material is injected to form a plug 103. In some forms of barrel, the cores together form a continuous core that extends longitudinally along and orthogonally across the cavity and around which the infill material flows to form the combined keyway and channels of the plug.

The moving core 121 comprises a central longitudinally elongated web 129 that intersects multiple pin bosses 130 that extend from opposed sides of the web, each pair of opposed protrusions forming pin channels 131 connected by a slotted aperture 132 in the barrel; the pin bosses preferably comprising substantially cylindrical bosses as shown in Fig 13 so that the channels correspondingly comprise substantially cylindrical recesses configured to receive substantially cylindrical pins. Importantly the slotted aperture132 has a width less than the diameter of the pin channels such that the guiding function of each channel 131 is not significantly affected. The web 129 is used to form part of the keyway by forming the slotted aperture 132 that extends from the surface of the plug till it becomes part of the keyway (the balance of the keyway being formed by the core 120). It should be understood that the portion of the aperture 132 from the' surface to the keyway

141 performs no function in the barrel but it is necessary to the casting process. The moving core 121 extends from face 133 to face 134 (corresponding to the features 135 and 136 respectively of the plug) and in the preferred form of the invention, are disposed slightly beyond the most outer bosses 130. The fixed core 120, shown in Fig 24, comprises a central longitudinally elongated substantially parallel-sided protrusion

142 that in part forms the axial guide channel 141 (or keyway 141) for the key. In alternative forms of the inventions the moving core may decrease in thickness (e.g. stepwise) toward the centre of the die.

The leading edge 122 of the fixed core 120 and leading edge 123 of moving core 121 are shaped so as to abut and they are preferably shaped to abut along an angled plane 137 as shown in Fig 21 and 22 and it can be seen from Fig 21 that the core 120 and web 129 together form a continuous key-like core that forms the keyway in the plug, the angled plane 137 satisfying geometric requirements while being suitable for the

casting process. The fixed and moving cores together also form a longitudinal channel 138 in the closed die that forms the fin 140 within the keyway 141 that mates within a guide channel in the key; the leading edge 122 of core 120 being shaped to incorporate a recessed shoulder 142 and the leading edge 123 of core 121 incorporates an opposed shoulder 143 that when the cores meet, the channel 138 is formed. Similarly, it is also possible to form another fin for an axial groove on the other side of the key by inclusion of a further shoulder in core 120 and inclusion of another recess shoulder in core 121 In this manner one or two fins can be provided while still allowing relative radial retraction of the cores from the cast plug. In casting practise, the pJug and moving recess 112 are displaced away from the fixed recess 110 and the cast plug is then ejected from the moving recess 112 as described below. In summary, the cores together also form the open ended channels 131 as shown in Fig 13; so together they form a continuous recess that includes the intersection of the pin channels 131 with the keyway 141 as well as the keyway and channels as described above. By referring to Fig 13, we see that the keyway 141 extends substantially the entire length of the plug but the first fin 140 extends longitudinally within the plug from the outer ends of features 135 and 136. The keyway is formed in the rear end by a blade like orthogonal extension 144 of the fixed core that protrudes sufficiently towards the moving half to form the keyway portion 145 shown in Fig 15 and to abut the surface 133 of the moving recess core and leave a recess 149 that is filled to comprise the bridge 146 Similarly, a blade like orthogonal extension 150 at the front end protrudes the same distance towards the moving core to form the wider recess 151 shown in Fig 13 and to abut the surface 134 of the moving recess 112 and leave a recess 152 that is filled to comprise the bridge 153 between the two halves 147 and 148 of the plug. Although the extension 144 and 150 could extend orthogonally from the fixed core 120 to abut the moving core 121 , good casting practice requires cores that abut along an angled surface hence the abutting surfaces 134 with 154 and 133 with1δ5 abut along planes inclined at an angle to the relative direction of movement of die halves, that in one form is 107 degrees. Good casting practice also requires cores to taper inwardly (a very small amount) as they extend from a surface and recesses to become slightly smaller as they deepen and although the models shown in the figures observe these requirements, it is not discernible by eye.

The plug may include a peripheral circfip groove 156 (formed by a raised annular inwardly protruding shoulder 157 of the cores) that may extend around the entire periphery of the barrel and the plug may include a drive pin 107 that is formed in recess 158 in the cavity

In one form, the die 109 further includes a, or a pair of opposed retractable sliding cores 160 shown in Fig 28 that extend into the plug cavity and are retractable axially to enable the casting to be removed; the sliding cores in common practice being supported by the moving half of the die. In some forms, each core 160 is configured as a pin 161 defined in part by a longitudinal axis that lies in the same plane in which the closed die halves abut. In relation to a die ready to receive the fill material, each pins 161 extends through mating apertures 163 in the walls of the plug cavity with half the aperture in the moving half and half in the fixed half; the pins may be substantially cylindrical in form to form substantially cylindrical fixing recesses 164 in the plug or they may be rectangular in cross-section and they may be stepped to include a portion of smaller cross-section towards the inner end as described above. Preferably there is a pair of opposed sliding cores to form a pair of opposed fixing recesses. The plug is further configured to includes side slots 165 formed by an inwardly protruding profiled shoulder 167 of the plug cavity 108 that extend across the moving and fixed recesses as shown in Fig 23 and 24. In some forms, each side slot 164 intersects (abutting or near abutting) a fixing recess 164 to provide a side opening to the fixing recess and a substantially uninterruptedly connection to an outwardly inclined surface 166 that participates in the connection of the head to the plug as described below. (In some cases the casting process may result in a very thin cast wall between the fixing recess 164 and the inclined surface 166 but if this will not be regarded as significantly affect the assembly of the barrel and hence can be considered to fall within the scope of "substantially uninterrupted")

In some forms, each shoulders 167 in plan view has an angled inner face and a first side that in the closed configuration of the die is adjacent to or abuts the leading end 168 of a pin 161 to form an uninterruptedly connection. Alternatively, the outwardly sloping surface 169 is formed by an end 170 of the sliding core 161 that has a profiled inner side 171 profiled as an outwardly disposed sloping surface and a planar surface 172 on the outer side that in the closed configuration of the die, extends across the shoulder 167 to either abut or be in close proximity to the shoulder 167 as shown between the closed dotted lines of Fig 28 to form an uninterruptedly connection. The die (or an associated die) includes a head cavity 115 to form the head, this cavity being disc-like in form and being defined by an axis that is orthogonal to the face of the die. The head cavity includes a head core 175 extending orthogonally from within a fixed recess 116 so that the leading edge 177 abuts the leading edge 178 of a similar core 179 extending orthogonally from within a moving recess 117 such that when the halves of the die abut (when the die is closed) the cavities 116 and 117 combine to form the dosed second cavity 115 while the fourth and fifth cores together comprise a

continuous core that extends across the second cavity 115 and about which fill material is pumped (or otherwise enabled to flow) to form disc-like head 102 having a keyway from one side to the other. The cores 175 and 179 have a cross-sectional shape substantially identical to the cross-section of the key blank (allowing for working clearances). Alternatively,. the cores 175 and 176 may be configured to have many different cross-sectional shapes to restrict entry to only those keys having a pre-determiπed mating cross-sectjon. In some forms the key has an longitudinally extended first side groove and one or more longitudinally extended second side grooves and the key way in the head has fins 140 and 140A and 140B etc that are received into the associated longitudinal grooves; the first fin 140 being afigned with and mating with the first fin 140 of the plug.

The head is further configured to include a spherical recess 180 in the outer face to assist key entry, this being formed by the raised spherical "mound" 181 in the head fixed recess 116. The head is further configured to include profiled fixing pins 182 that extend longitudinally from the underside of the head as shown in Fig 13; these fixing pins being formed within elongated recesses 183 that extend from the floor of the head moving recess.

The head is further configured to include a profiled substantially rectangular abutment 184 that surrounds the keyway 141 and extends longitudinally to occupy the wider recess 151 ; this being formed within the floor of the head moving recess 117. During the casting process, the moving die half displaces from the fixed die half carrying the casting/s within the moving recess/es; at a later time in the casting process ejectors (that extend orthogonally through the die to comprise parts of the wall of the moving recess) push forward relative to the moving recess to dislodge the casting from the moving recesses. In the case of the plug, ejectors have passage through apertures 188 in the floor of the moving recess, they comprising wall portions of the plug cavity. Similarly in the case of the head, ejectors have passage through apertures 185 in the floor of the moving recess to comprise floor portions in the cavity.

Each fixing pin 182 and its associated fixing recess 164 is configured such that the trailing portion 189 of the pin fits through the opening 190 to the fixing recess 164 with not more than a very small clearance and the leading end 191 of the fixing pin is configured to have passage with minimal clearance through an aperture 192 at the end of the fixing recess that is adjacent to the sloping face 166. The head is attached to the plug by aligning each fixing pin 182 with an associated fixing recess 164 and displacing the head axially towards the plug (by the application of an axial force towards the plug) until the leading ends 191 of the fixing pins have passed through apertures 192 to abut the sloping faces 166. Further displacement causes each leading end 191 to displace along

the sloping faces 1δ6 (while deforming) to displace sideways to overlap the wall of the aperture 192 (that in part comprises the fixing shoulder 13, during which displacement, the walls of the aperture 192 restrain the fixing pin from displacing sideways as described above. To remove the head from the plug would require each leading end 192 to be straightened by being drawn through the aperture 192 by the application of a force to the head away from the plug, in effect, this force acts to resistance removal of the head In a particular form, the trailing portion 189 of the fixing pin is substantially square in cross- section while the leading end 192 is generally rectangular in cross section having a reduced width d2 in the direction the leading end is deflected; i.e. where d2 < d1 where di is the cross-sectional width in the orthogonal direction.

In particular forms, the head and fixing pins are within a single cast member that in a particular form comprises a zinc die cast member and in a more particular form is unplated or zinc plated or chrome or nickel plated. In particular forms, the plug/s and fixing recess/es are within a single cast member that in a particular form comprises a zinc die cast member and in a more particular form is unplated or zinc plated or chrome or nickel plated and in another particular form comprises a single plastic moulding. In a particular the head is nickel plated and the plug is differently surface finished and may be unplated or zinc plated. Some features of a barrel so cast are: it is relatively inexpensive; the variation in quality is minimal and not substantially dependent on set up and tool wear as are machined parts, the head may be plated in one finish while the plug is either not plated or plated in a different finish