Adjustable Door Lockset Jig for Accurate Backset Hole Placement
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Solution Overview
Problem
Current lockset jigs for doors require multiple jigs for different backset options and can be damaged by hole saws, complicating the process of accurately placing bore holes and ensuring proper spacing for door handle assemblies.
Innovation Solution
A cutting guide apparatus with an adjustable engagement interface and backset assembly that allows for interchangeable handle hole guides, enabling precise placement of bore holes and accommodating various backset distances without damaging the jig, using a design with pivotable arms and adjustable mounting brackets to center the edge bore guide and handle hole guide.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple jigs are used to accommodate different backset options, then various backset distances can be achieved, but device complexity increases
Solution Approach 1:
The jig is designed with an adjustable backset assembly that allows a single device to accommodate multiple backset distances (2-3/8 inches and 2-3/4 inches) through repositionable mounting brackets and interchangeable handle hole guides, eliminating the need for multiple separate jigs while maintaining versatility across different door configurations
Solution Approach 2:
The backset assembly incorporates movable and adjustable components including repositionable mounting brackets and interchangeable guides that can be dynamically reconfigured between different backset positions, allowing the jig to adapt to various door thicknesses and handle assembly configurations without requiring multiple fixed devices
2Productivity
If hole saws are used to cut bore holes, then efficient hole creation is achieved, but the jig can be damaged at the edges of the bore hole
Solution Approach 1:
The patent introduces a protective sacrificial layer or backing plate positioned between the hole saw blade and the jig structure, which absorbs the harmful impact of the hole saw cutting action, preventing damage to the precision components of the jig while allowing efficient hole cutting to proceed
Solution Approach 2:
The jig design incorporates protective features such as sacrificial edges or reinforced positioning structures that are placed in advance at critical locations where hole saws will make contact, cushioning against potential damage before it occurs and preserving the integrity of the adjustable backset assembly
3Manufacturing precision
If precise backset spacing is maintained, then proper door handle assembly installation is achieved, but the jig requires complex adjustment mechanisms
Solution Approach 1:
The backset assembly is divided into modular segments including separate mounting brackets, interchangeable guides, and adjustable components that can be independently positioned and locked, allowing precise backset spacing to be achieved through simple modular adjustments rather than complex continuous mechanisms
Data Source
AI summary
A cutting guide apparatus for guiding placement of bore holes in a door may include an engagement interface and a backset assembly. The engagement interface is configured to retain the apparatus proximate to an edge of a door and center an edge bore guide between an inside face and an outside face of the door. The engagement interface includes a first arm and a second arm that are each operably coupled to a common pivot axis. The backset assembly is operably coupled to the engagement interface to enable an amount of backset from the edge of the door to a center of a handle hole guide to be adjusted. The backset assembly includes a first mounting bracket operably coupled to a first portion of the first arm and a first portion of the second arm, and a second mounting bracket operably coupled to a second portion of the first arm.