Adjustable motor cylinder for door thickness

Abstract

The invention relates to a motorized cylinder assembly adaptable to varying door thicknesses, offering enhanced flexibility, durability, and ease of installation. The assembly includes a motorized housing containing a motor, gear system, spindle, PCB, and rechargeable batteries, paired with a cylinder connected through interchangeable couplings. A door connection apparatus provides secure mounting and alignment. The motorized housing adjusts the cylinder's position using a gear-driven spindle, ensuring compatibility with a wide range of door sizes. Integrated Bluetooth connectivity allows remote operation, while a USB port enables convenient recharging. This innovation simplifies manufacturing, reduces installation complexity, and improves user convenience and security.

Description

[0001] ADJUSTABLE MOTOR CYLINDER FOR DOOR THICKNESS

[0002] Technical Field of the Present Invention

[0003] The present invention relates to adjustable motorized cylinders, particularly those used in the construction and locking industries. Specifically, the invention pertains to a motorized cylinder assembly adaptable to various door thicknesses, ensuring enhanced operational flexibility and cost efficiency in door locking systems.

[0004] Background of the Invention

[0005] In motorized locking systems, the lack of adaptability for varying door thicknesses remains a significant challenge. Below, three prior art documents are analyzed to highlight the technological gaps that the present invention addresses.

[0006] One of the prior art references in the present field can be suggested as US6012310A: This patent describes a motorized lock assembly that includes a motor and gear mechanism to actuate the locking bolt. While it offers motorized locking, it does not address adjustability for different door thicknesses, necessitating multiple cylinder sizes for various applications.

[0007] Another reference is US4829862A disclosing a modular locking system designed for machine tools, focusing on interlocking components for secure assembly. Although it introduces a modular approach, it is not tailored for door locking mechanisms and does not provide solutions for adjustable cylinder lengths in door locks.

[0008] Another reference is US20170051533A1 discussing a motorized cylindrical lock capable of both mechanical and remote electronic actuation. However, it lacks features for adjusting to various door thicknesses, limiting its versatility across different installations.

[0009] These references highlight existing solutions in motorized and modular locking systems but do not adequately address the need for a universally adjustable cylinder length to accommodate doors of varying thicknesses without compromising security or ease of installation.

[0010] Therefore, these prior solutions highlight a common issue: the inability to provide a single, robust locking system adaptable to a broad range of door thicknesses. Fixed- length designs require multiple cylinder variants, modular systems introduce mechanical complexity and potential failure points, and adjustable cylinders often sacrifice ease of use and long-term reliability.

[0011] The present invention overcomes these limitations by introducing an innovative motorized cylinder assembly that seamlessly adapts to a wide range of door thicknesses without requiring additional parts or complex adjustments. It simplifies installation, reduces manufacturing and inventory costs, and ensures durability over extended use.

[0012] Summary of the Invention

[0013] The present invention introduces a motorized cylinder assembly designed to overcome the adaptability challenges of existing locking systems by providing a seamless solution for doors of varying thicknesses. This innovative design eliminates the need for multiple cylinder sizes, extension parts, or complex adjustment mechanisms, streamlining production, storage, and installation processes.

[0014] The invention features an adjustable motor housing, a cylinder component, and a set of couplings of varying lengths. These components allow the cylinder to adapt to different door thicknesses without requiring specialized tools or advanced technical expertise. The motor housing incorporates a gear and spindle mechanism that ensures precise alignment and easy configuration during installation.

[0015] A key aspect of the invention is its universal compatibility, which enables a single product to accommodate a broad range of door thicknesses. The adjustable components simplify the installation process, allowing users to customize the cylinder configuration effortlessly. By eliminating the need for additional extension parts, the invention enhances structural integrity and reduces the risk of mechanical failure over time. Furthermore, the streamlined design minimizes production and inventory costs by removing the necessity for multiple cylinder variants.

[0016] This motorized cylinder assembly not only addresses the limitations of prior art but also improves operational efficiency and user convenience. Its robust, adaptable, and cost- effective design represents a significant advancement in motorized locking systems, meeting the needs of modem applications while enhancing performance and reliability.

[0017] Brief Description of the Drawings The following drawings illustrate various components and configurations of the motorized cylinder assembly designed for adjustable door thickness compatibility:

[0018] Figure 1 : Shows the primary components of the product, including the cylinder (1 ), door connection apparatus (2), centering element, motorized housing (3), long connection element (4), and connection element (5).

[0019] Figure 2: Illustrates the internal structure of the motorized housing, detailing elements such as the gear group (7), rotating spindle (8), motor unit (9), PCB group (10), and the rotating cap cover (11 ). The motorized housing is shown disassembled to highlight the arrangement of these parts.

[0020] Figure 3: Depicts the assembly process, demonstrating how the door connection apparatus is attached to the door (13), the centering element is aligned, the cylinder is inserted through the door (14), and the motorized housing is secured within the apparatus (15). The figure also shows how the appropriate connection element is selected and fitted (16), and how the assembly is aligned and locked using the set screw (17).

[0021] Figure 4: Displays examples of the system installed on doors of different thicknesses. Sub-figures show configurations for thick doors (a) with a long coupling (4), medium doors (b) with a short coupling (5), and thin doors (c) where the motorized housing is positioned partially outside the door for optimal alignment.

[0022] These figures provide a comprehensive visual representation of the components, assembly steps, and adaptable configurations of the invention.

[0023] Detailed Description of the Present Invention

[0024] The invention consists of the following primary components, as illustrated in the drawings:

[0025] Cylinder (1 ): The core locking component that transfers rotational or linear motion to the locking mechanism.

[0026] Door Connection Apparatus (2): A structure designed to permit internal forward and backward linear movement and that securely attaches the assembly to the door while providing adjustment capabilities. Motorized Housing (3): Contains the motor, gear system, and spindle mechanism, enabling precise adjustment and locking operations.

[0027] Long Coupling (4): Used for connecting the motorized housing and the cylinder in cases of thick doors.

[0028] Short Coupling (5): Designed for use with thinner doors, ensuring a proper fit and alignment.

[0029] USB Port (6): Provides access for recharging the built-in battery.

[0030] Gear Group (7): A set of gears within the motorized housing that adjusts rotational speed and torque.

[0031] Rotating Spindle (8): Converts the motor's motion into precise linear adjustments.

[0032] Motor Unit (9): Powers the locking system and drives the spindle via the gear group.

[0033] PCB Group (10): Integrates Bluetooth connectivity and other electronic control functions for remote operation.

[0034] Rotating Cap Cover (11 ): Encases and secures the spindle, providing an accessible interface for manual adjustments.

[0035] Rechargeable Batteries (12): Supplies power to the system, recharged through the USB port.

[0036] Door Connection Screws (13): These are screws designed to securely fasten the door connection apparatus (2) to the door. They ensure a stable and firm installation by anchoring the apparatus into the door’s surface.

[0037] Safety Plate (14): A metal sheet or plate that slides through a rectangular slot in the door connection apparatus (2). It acts as a stabilizing component, preventing lateral movement of the motorized housing (3) and enhancing the overall rigidity of the assembly.

[0038] Motorized Housing Insertion Mechanism (15): Refers to the structural and alignment features within the door connection apparatus (2) that facilitate the smooth insertion of the motorized housing (3). This mechanism ensures that the housing aligns correctly with the connection apparatus during installation. Coupling Selection (16): The process of choosing either the long coupling (4) or short coupling (5) based on the thickness of the door. This selection ensures proper connection and alignment between the motorized housing (3) and the cylinder (1 ) for optimal performance.

[0039] Setscrew (17): A locking screw used to secure the motorized housing (3) within the door connection apparatus (2). After the assembly is aligned to accommodate the door thickness, the setscrew (17) locks the housing in place to prevent unintentional movement or misalignment during operation.

[0040] 18 and 19 based on Fig. 4: The motorized housing is connected to the door connection apparatus without any gap (18), and a long connection element (4) is used between the motorized housing and the cylinder. For a medium-section door (b), the door connection apparatus and the motorized housing are connected without any gap, and a short connection element (5) is selected to adjust the connection distance. For a th insection door (c), the short connection element (5) is selected, and the motorized housing is connected to the door connection apparatus with a gap (19).

[0041] The present invention provides a centering element in the form of a structure that ensures the alignment of the door connection apparatus (2) and the motorized housing (3).

[0042] The present invention provides a motorized cylinder assembly designed to adapt to various door thicknesses. The assembly combines advanced structural components with user-friendly functionalities to ensure a secure, durable, and easy-to-install locking mechanism. The cylinder (1 ) serves as the core locking mechanism of the assembly. Constructed from durable metal alloys to withstand high levels of mechanical stress, the cylinder (1 ) includes a central bore that allows the transfer of rotational or linear motion from the motorized housing (3) to the locking bolt. It interacts with the motorized housing (3) via couplings (4, 5), receiving precise motion to lock or unlock the door, and its compatibility with varying door thicknesses is achieved through the adjustable connection provided by the couplings (4, 5).

[0043] The door connection apparatus (2) is a rigid frame designed to securely attach the motorized cylinder assembly to the door. It includes adjustable slots for precise alignment and pre-drilled holes for screws to ensure a stable fit. This apparatus (2) anchors the entire assembly and provides a stable interface for connecting the motorized housing (3) to the cylinder (1 ), allowing fine adjustments during installation to ensure proper alignment between the locking mechanism and the door’s structural features.

[0044] The motorized housing (3) is a robust casing that contains the motor (9), gear system (7), spindle (8), PCB (10), and batteries (12). Made from high-strength plastic or metal to protect internal components, the housing (3) converts electronic signals into mechanical motion, adjusts the cylinder’s position relative to the door thickness, and manages operations such as Bluetooth connectivity and power regulation.

[0045] The couplings (4, 5) are cylindrical connectors made from high-strength materials to ensure a reliable transfer of motion. The long coupling (4) is used for thicker doors, while the short coupling (5) accommodates thinner doors. These couplings (4, 5) bridge the gap between the motorized housing (3) and the cylinder (1 ), allowing the assembly to adapt to various door thicknesses without compromising structural integrity or functionality.

[0046] The USB port (6) is integrated into the motorized housing (3), providing an accessible interface for recharging the battery. It allows users to recharge the assembly without disassembling the system, ensuring continuous operation and minimizing maintenance.

[0047] The gear group (7) consists of precision-engineered gears housed within the motorized unit (3). These gears (7) transmit torque efficiently from the motor (9) to the rotating spindle (8), adjusting rotational speed and torque for precise control. The spindle (8), a threaded shaft connected to the gear group (7), extends or retracts the motorized housing (3) relative to the cylinder (1 ), enabling smooth alignment during installation and operation.

[0048] The motor (9), powered by rechargeable batteries (12), drives the gear group (7) and spindle (8), providing the mechanical force required for locking, unlocking, and positional adjustments. The PCB (10), a compact electronic board integrated into the motorized housing (3), manages remote control signals, processes user commands, and communicates with smart home systems. It regulates battery usage and monitors system performance. The rotating cap cover (11 ) encases the spindle (8) and provides an interface for manual adjustments if necessary. It protects the spindle (8) from environmental exposure while allowing users to manually rotate it during setup or maintenance. The rechargeable batteries (12), housed within the motorized unit (3), ensure uninterrupted operation and can be recharged via the USB port (6).

[0049] During installation, the door connection apparatus (2) is secured to the door using screws. The cylinder (1 ) is inserted from the opposite side of the door and connected to the motorized housing (3) using either the long coupling (4) or short coupling (5), depending on the door thickness. The motorized housing (3) is slid into the connection apparatus (2) and locked in place with a setscrew. The PCB (10) manages commands received via Bluetooth or manual inputs, activating the motor (9) to drive the gear group (7) and spindle (8), which adjusts the cylinder (1 ) position or initiates the locking / unlocking sequence. The couplings (4, 5) transfer motion from the motorized housing (3) to the cylinder (1 ), ensuring smooth and precise operation.

[0050] This coordinated interaction between the structural components and their functionalities enables the assembly to adapt to various door configurations while maintaining durability and ease of use. The design’s advanced features, including remote control and rechargeable power, further enhance its utility, making it an ideal solution for modem locking systems.

[0051] In an aspect of the invention, a motorized cylinder assembly adaptable to doors of varying thicknesses is proposed, the latter comprising: a cylinder (1 ) configured to transmit rotational or linear motion to a locking mechanism; a motorized housing (3) containing a motor (9), a gear group (7), a spindle (8), a PCB (10), and rechargeable batteries (12), the motorized housing (3) being operable to adjust the position of the cylinder (1 ) relative to the door; at least one coupling (4, 5) to connect the motorized housing (3) to the cylinder (1 ), the coupling (4, 5) selected based on the thickness of the door; a door connection apparatus (2) configured to secure the assembly to a door while allowing positional adjustments; and a USB port (6) for recharging the rechargeable batteries (12).

[0052] In another aspect of the invention, the motorized housing (3) further comprises a rotating cap cover (11 ) configured to encase the spindle (8) and allow manual adjustments. In another aspect of the invention, the PCB (10) includes Bluetooth connectivity for receiving remote commands and monitoring system performance.

[0053] In another aspect of the invention, the door connection apparatus (2) being configured to permit internal forward and backward linear movement, includes adjustable slots and pre-drilled holes for secure alignment and attachment to the door.

[0054] In another aspect of the invention, the gear group (7) adjusts rotational speed and torque to provide precise linear motion through the spindle (8).

[0055] In another aspect of the invention, wherein the cylinder (1 ) is made of a durable metal alloy for enhanced structural integrity.

[0056] In another aspect of the invention, long (4) and short (5) connection elements are provided to accommodate a range of door thicknesses.

[0057] In another aspect of the invention, the rechargeable batteries (12) are lithium-ion batteries.

[0058] In another aspect of the invention, the PCB (10) is configured to regulate battery power and enable smart home integration.

[0059] In another aspect of the invention, the spindle (8) has a threaded design to allow precise linear adjustments of the cylinder (1 ).

[0060] In another aspect of the invention, a method of mounting a motorized cylinder assembly on a door is proposed, the method comprising: securing a door connection apparatus (2) to a door using screws; inserting a cylinder (1 ) through an opening in the door; selecting a coupling (4, 5) based on the thickness of the door; connecting the cylinder (1 ) to a motorized housing (3) using the selected coupling (4, 5); sliding the motorized housing (3) into the door connection apparatus (2); enabling length adjustment through forward / backward linear motion by aligning the centering element; aligning the motorized housing (3) with the cylinder (1 ) and securing it in position using a setscrew.

[0061] In another aspect of the invention, the method further comprises the step of recharging the rechargeable batteries (12) of the motorized housing (3) via a USB port (6) prior to operation. In another aspect of the invention, the alignment of the motorized housing (3) is adjusted by manually rotating a cap cover (11 ) encasing the spindle (8).

[0062] In another aspect of the invention, the method further comprises the step of pairing the motorized housing (3) with a Bluetooth-enabled device for remote operation and monitoring.

[0063] In another aspect of the invention, the centering element and the door connection apparatus (2) are adjusted to align the motorized housing (3) with the locking mechanism of the door.

[0064] The motorized cylinder assembly described in this invention incorporates advanced alignment and adaptability mechanisms to ensure seamless operation across doors of varying thicknesses. These mechanisms are facilitated by key components, including the centering element), gapless connection element (18), and gapped connection element (19), as well as the couplings (4, 5). Each component is designed to function independently or in combination to provide precise alignment, secure connections, and efficient adaptability during installation and operation.

[0065] The centering element plays an important role in maintaining alignment between the door connection apparatus (2) and the motorized housing (3). This component is positioned within the door connection apparatus (2), ensuring the motorized housing (3) aligns precisely with the cylinder (1 ) and couplings (4, 5).

[0066] In the default embodiment, the centering element is integrated into the door connection apparatus (2) as a rigid, adjustable structure. It permits forward and backward motion during length adjustment, ensuring that the motorized housing (3) remains aligned with the cylinder (1 ) during operation.

[0067] In another configuration, the centering element (20) may be an independent plate or guide installed between the motorized housing (3) and the door connection apparatus. This detachable version simplifies maintenance and replacement, providing additional flexibility in manufacturing.

[0068] The gapless connection element (18) ensures a rigid and secure connection between the motorized housing (3) and the door connection apparatus (2). It is important for installations involving medium-section doors (b) or thick-section doors (a), where a firm and direct connection is required to prevent misalignment or mechanical instability. The gapless connection element (18) is typically a structural part of the door connection apparatus (2), molded or machined to create a tight interface with the motorized housing (3). Its material composition, often a high-strength alloy or composite, enhances durability under prolonged mechanical stress.

[0069] In some embodiments, the gapless connection element (18) may include an adjustable locking mechanism, such as a setscrew (17), allowing users to fine-tune the connection based on specific installation conditions.

[0070] For thin-section doors (c), the gapped connection element (19) introduces a controlled spacing between the motorized housing (3) and the door connection apparatus (2). This component ensures that the system remains adaptable while maintaining operational stability.

[0071] The gapped connection element (19) may be implemented as a spacer ring or an adjustable bracket. In its simplest form, it is a static component that is installed during assembly. Alternatively, it could be a dynamic element, such as a spring-loaded spacer, providing self-adjusting capabilities for various door thicknesses.

[0072] While the gapped connection element (19) is generally positioned within the door connection apparatus (2), an alternate design could integrate it directly into the motorized housing (3) as part of the insertion mechanism (15). This would simplify the assembly process and reduce the number of standalone components.

[0073] The couplings (4, 5) connect the motorized housing (3) to the cylinder (1 ), with their selection based on door thickness. The long coupling (4) is used for thicker doors, while the short coupling (5) accommodates thinner doors.

[0074] Both couplings are made from durable metal alloys or reinforced composites to ensure reliable motion transfer and resist wear over time. They are designed with threaded ends to simplify attachment to both the motorized housing (3) and the cylinder (1 ).

[0075] The couplings may be manually screwed into place during installation or feature a quick-connect mechanism for tool-free assembly. In alternative embodiments, the couplings (4, 5) could include integrated alignment guides or locking tabs to further streamline the setup process.

[0076] The interplay between the centering element, gapless connection element (18), gapped connection element (19), and couplings (4, 5) ensures the motorized cylinder assembly adapts seamlessly to varying door thicknesses without compromising alignment or stability. For example:

[0077] In thick-section doors (a), the centering element works alongside the gapless connection element (18) and the long coupling (4) to create a direct, robust connection between the motorized housing (3) and the door connection apparatus (2).

[0078] In medium-section doors (b), the centering element (20) and the short coupling (5) facilitate precise alignment and secure attachment, eliminating the need for additional adjustments.

[0079] In thin-section doors (c), the gapped connection element (19) provides the necessary spacing to accommodate the thinner door while maintaining proper alignment through the centering element and short coupling (5).

[0080] The exact placement of the centering element within the assembly can be configured such that it is designed to sit flush within the door connection apparatus (2), providing a stable base for the motorized housing (3) and ensuring precise alignment during installation and operation. Alternatively, the centering element can directly contact the motorized housing (3), it may act as a guiding interface, facilitating linear motion and maintaining the correct positioning of the assembly components.

[0081] This comprehensive alignment and adaptability system not only addresses the limitations of prior art but also enhances the usability and durability of the motorized cylinder assembly. By incorporating alternative embodiments for critical components, the design ensures compatibility with a broad range of installation scenarios, offering unparalleled flexibility and operational efficiency.

Claims

CLAIMS1 ) A motorized cylinder assembly adaptable to doors of varying thicknesses, comprising: a cylinder (1 ) configured to transmit rotational motion to a locking mechanism; a motorized housing (3) containing a motor (9), a gear group (7), a spindle (8), a PCB (10), and rechargeable batteries (12), the motorized housing (3) being operable to adjust the position of the cylinder (1 ) relative to the door; at least one connection element (4, 5) to connect the motorized housing (3) to the cylinder (1 ), the coupling (4, 5) selected based on the thickness of the door; a door connection apparatus (2) configured to enable length adjustment and secure the assembly to a door while allowing positional adjustments and; a centering element designed to align the motorized housing (3) with the door connection apparatus (2).2) The motorized cylinder assembly of claim 1 , wherein the motorized housing (3) further comprises a rotating cap cover (11 ) configured to encase the spindle (8) and allow manual adjustments.3) The motorized cylinder assembly of claim 1 , wherein the PCB (10) includes Bluetooth connectivity for receiving remote commands and monitoring system performance.4) The motorized cylinder assembly of claim 1 , wherein the door connection apparatus (2) includes adjustable slots and pre-drilled holes for secure alignment and attachment to the door.5) The motorized cylinder assembly of claim 1 , wherein the gear group (7) adjusts rotational speed and torque to provide precise motion through the spindle (8).6) The motorized cylinder assembly of claim 1 , wherein the cylinder (1 ) is made of a durable metal alloy for enhanced structural integrity.7) The motorized cylinder assembly of claim 1 , further comprising long (4) and short (5) couplings to accommodate a range of door thicknesses.8) The motorized cylinder assembly of claim 1 , wherein the rechargeable batteries (12) are lithium-ion batteries.9) The motorized cylinder assembly of claim 1 , wherein the PCB (10) is configured to regulate battery power and enable smart home integration.10) The motorized cylinder assembly of claim 1 , wherein the spindle (8) has a threaded design to allow precise adjustments of the cylinder (1 ).11 ) The motorized cylinder assembly of claim 1 , wherein it comprises a USB port (6) for recharging the rechargeable batteries (12).12) A method of mounting a motorized cylinder assembly on a door, the method comprising: securing a door connection apparatus (2) to a door using screws; inserting a cylinder (1 ) through an opening in the door; selecting a connection element (4, 5) based on the thickness of the door; connecting the cylinder (1 ) to a motorized housing (3) using the selected connection element (4, 5); sliding the motorized housing (3) into the door connection apparatus (2); aligning the motorized housing (3) with the cylinder (1 ) and securing it in position using a setscrew and; enabling length adjustment by aligning a centering element through forward / backward linear motion.13) The method of claim 12, further comprising recharging the rechargeable batteries (12) of the motorized housing (3) via a USB port (6) prior to operation.14) The method of claim 12, wherein the alignment of the motorized housing (3) is adjusted by manually rotating a cap cover (11 ) encasing the spindle (8).15) The method of claim 12, further comprising pairing the motorized housing (3) with a Bluetooth-enabled device for remote operation and monitoring.16) The method of claim 12, wherein the door connection apparatus (2) is adjusted to align the motorized housing (3) with the locking mechanism of the door.

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