Adjustable Backset Deadbolt Assembly with Helical Slot
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Solution Overview
Problem
Deadbolt assemblies are typically designed for specific backset dimensions, requiring separate assemblies for 2⅜ inches and 2¾ inches, which is inconvenient for both manufacturers and consumers.
Innovation Solution
An adjustable backset deadbolt assembly that allows for axial movement of the bolt between retracted and extended positions, featuring a helical slot in the outer bolt housing and a protrusion in the inner bolt housing for adjustable backset dimensions, enabling rotation to switch between 2⅜ inches and 2¾ inches settings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate deadbolt assemblies are produced for different backset dimensions (2⅜ inches and 2¾ inches), then manufacturing precision and reliability for each specific dimension is improved, but device complexity and production costs increase
Solution Approach 1:
The deadbolt assembly is designed with a universal adjustment mechanism that allows a single assembly to accommodate multiple backset dimensions (2⅜ inches and 2¾ inches). The inner bolt housing can be rotated to different angular positions, with detent features providing positive positioning at each backset setting, enabling one assembly to perform multiple functions that previously required separate assemblies
Solution Approach 2:
The bolt housing is made rotatable relative to the outer housing, transforming a static fixed-backset design into a dynamic adjustable design. This rotation capability allows the backset dimension to be changed by approximately 360 degrees, with detent features providing stable positioning at each predetermined backset value, thus resolving the contradiction between reliability and complexity
2Adaptability or versatility
If multiple deadbolt assembly variants are manufactured for different backset dimensions, then adaptability to different applications is improved, but manufacturing costs and inventory complexity increase
Solution Approach 1:
A single deadbolt assembly design incorporates adjustment capabilities for multiple backset dimensions through the rotatable inner bolt housing mechanism. This universal design eliminates the need for manufacturers to produce and maintain separate assembly variants for different backset dimensions, reducing production costs and inventory complexity while maintaining adaptability to different applications
Solution Approach 2:
The adjustment mechanism is segmented into distinct functional components: the rotatable inner bolt housing, the helical slot for axial movement translation, and the detent features for positive positioning. This segmentation allows the single assembly to be easily adjusted between different backset dimensions without requiring complete redesign or multiple assembly variants
3Ease of manufacture
If a fixed backset design is used, then manufacturing simplicity is improved, but adaptability to different installation requirements deteriorates
Solution Approach 1:
The design transitions from a fixed backset configuration to a dynamic adjustable configuration by enabling rotation of the inner bolt housing. The rotation is constrained by detent features that provide stable positioning at predetermined backset dimensions, maintaining manufacturing simplicity while achieving adaptability to different installation requirements
Data Source
AI summary
An adjustable backset deadbolt assembly providing operational and structural improvements. The deadbolt assembly can provide adjustability between a first backset dimension and a second backset dimension for allowing installation in doors conforming to various industry standards. The deadbolt assembly can provide adjustability between backset dimensions by relative rotation between the inner bolt housing and the outer housing. The inner bolt housing may be provided with a depressible snap finger to allow insertion of a protrusion thereon into a slot in the outer housing. In some embodiments, the slot is provided substantially helically through an angle of 360 degrees to provide common orientation of parts in each backset dimension. The outer housing may be provided to integrally form a cam housing and a bolt housing.