Bidirectional Clutch Power Boost Module for ADA Compliant Door Closers
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Solution Overview
Problem
Standard mechanical door closers often fail to meet the Americans with Disabilities Act's requirement of a maximum 5-pound opening force, leading to doors getting stuck open due to varying pressures, which affects security and HVAC efficiency, and existing solutions like auto operators or electronic closers are not feasible in all retrofit situations due to cost and waste concerns.
Innovation Solution
A door closer assembly with a bidirectional clutch, motor, and control system that allows the pinion to rotate bidirectionally without transmitting rotation to the motor shaft, sensing its position, and driving the motor to adjust the pinion to a desired position, providing a power boost to ensure doors can be closed securely without excessive opening force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the preload on springs is reduced to meet the maximum opening force requirement, then the opening force is reduced to 5 pounds, but the closing force becomes insufficient causing doors to get stuck open
Solution Approach 1:
The door closer system is segmented into two independent force sources: a mechanical spring system for closing force and an electric motor for supplemental closing assistance. This allows the spring preload to be optimized for low opening force while the motor provides additional closing power when needed, resolving the contradiction between gentle opening and reliable closing.
Solution Approach 2:
The patent replaces part of the mechanical spring-based closing system with an electric motor system. The motor can provide supplemental closing force on demand without requiring increased spring preload, thus maintaining low opening force while improving closing reliability through electronic actuation.
2Reliability
If an auto operator is installed to ensure doors close properly, then door closing reliability is improved, but installation complexity and cost increase significantly
Solution Approach 1:
The power boost module is designed as a universal retrofit component that can be integrated with existing mechanical door closer systems. It provides automated door closing assistance through a standardized interface, enabling reliable operation without requiring complete system replacement or complex custom installation.
Solution Approach 2:
The bidirectional clutch acts as an intermediary between the motor and the door closer mechanism. It allows the motor to engage with the pinion only when supplemental force is needed, while permitting the mechanical spring system to operate independently during normal opening and closing cycles, thus simplifying the overall system architecture.
3Force
If an electronic door closer with motor is installed to provide additional closing force, then closing force is improved, but the entire closer assembly must be replaced creating waste
Solution Approach 1:
The solution segments the door closer system into a reusable mechanical core (spring system, pinion, armature) and a replaceable power boost module. Only the modular motor assembly needs to be installed or replaced, while the existing mechanical components remain in service, thereby minimizing waste and enabling component-level upgrades.
Solution Approach 2:
The patent enables recovery and reuse of the existing mechanical door closer components by adding a separate motor module. The bidirectional clutch allows the motor to drive the pinion independently when needed, while the mechanical spring system continues to function and can be retained, reducing material waste compared to complete assembly replacement.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution ensures doors can be closed securely while maintaining a low opening force, addressing the issue of stuck doors and improving HVAC efficiency by providing a modular, cost-effective power boost that integrates with existing door closer systems.
Implementation Method 1
a bidirectional clutch connected between the pinion and the motor shaft. The method generally involves permitting, by the bidirectional clutch, rotation of the pinion in each of a first direction and a second direction without transmitting rotation of the pinion in either direction to the motor shaft
Implementation Method 2
driving the motor to rotate the motor shaft; and by the bidirectional clutch, coupling the motor shaft with the pinion in response to rotation of the motor shaft
Implementation Method 3
by the bidirectional clutch, coupling the motor shaft with the pinion in response to rotation of the motor shaft, thereby transmitting torque from the motor shaft to the pinion and urging the pinion toward the desired rotational position
Data Source
AI summary
An exemplary method relates to operating a door closer assembly including a closer body, a pinion rotatably mounted to the closer body, a motor including a motor shaft, and a bidirectional clutch connected between the pinion and the motor shaft. The method generally involves permitting, by the clutch, rotation of the pinion in each of a first direction and a second direction without transmitting rotation of the pinion in either direction to the motor shaft; sensing, with a sensor, a rotational position of the pinion; comparing, by a controller, the rotational position of the pinion with a desired rotational position; based upon the comparing, driving the motor to rotate the motor shaft; and by the clutch, coupling the motor shaft with the pinion in response to rotation of the motor shaft, thereby transmitting torque from the motor shaft to the pinion and urging the pinion toward the desired rotational position.