Door Catch with Adjustable Ball Plunger for Sag Prevention
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Solution Overview
Problem
Existing door catch designs face challenges in adjusting catch tension post-installation without removing or moving mounting members, and they often fail to prevent door sagging over time, especially in heavy or tall doors.
Innovation Solution
A door catch design featuring a ball plunger assembly, catch bar bracket, and ball catch base with adjustable frictional force, allowing for post-installation tension adjustment without removing mounting members, and incorporating features like threaded apertures and serrated surfaces to prevent slippage and maintain door alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional door catch designs are used with fixed mounting members, then installation is simple, but catch tension cannot be adjusted post-installation without drilling new holes
Solution Approach 1:
The ball plunger assembly incorporates a threaded body that allows dynamic adjustment of the ball's position along the thread. By rotating the ball plunger body using the tool-receiving pattern, the ball can be moved to different positions to adjust catch tension. This dynamic adjustment mechanism eliminates the need for fixed mounting holes while providing continuous tension control capability.
Solution Approach 2:
The threaded aperture in the ball catch base acts as an intermediary mechanism between the ball plunger assembly and the mounting structure. The threads provide a mechanical interface that converts rotational motion into linear displacement of the ball, enabling precise tension adjustment without requiring direct access to mounting holes or structural modifications.
2Ease of operation
If mounting members are removed or moved to adjust catch tension, then tension can be adjusted, but installation time increases and mounting holes must be drilled
Solution Approach 1:
The ball plunger assembly is designed to be self-adjusting through the threaded mechanism. The tool-receiving pattern allows the user to independently adjust the ball position without needing to remove mounting members or drill new holes. The adjustment is performed in-place by simply rotating the ball plunger body, making the system self-serviceable and eliminating time-consuming installation modifications.
3Strength
If door catch components are designed to sustain heavy door forces, then door sag is prevented, but friction between components may cause slippage
Solution Approach 1:
The patent replaces reliance on friction alone with a threaded mechanical engagement system. The ball plunger body threads into the ball catch base, creating a positive mechanical connection that sustains door forces. This mechanical substitution eliminates slippage by using threaded engagement rather than friction-based holding, providing reliable force transmission even under heavy door loads.
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 design effectively prevents door sagging and allows for micro-adjustments of catch tension, ensuring the door remains properly aligned and operational over time without requiring new holes or member relocation.
Implementation Method 1
the ball and detent frictionally engage to hold the door open when the door is in an extended position
Implementation Method 2
The exterior of the ball plunger body is threaded. The ball catch base also includes a threaded aperture and the ball plunger assembly is threaded into the threaded aperture
Data Source
AI summary
Disclosed is a door catch that can help to prevent door sag, especially for heavy or tall residential or commercial doors, and provides for post-installation catch tension adjustment without removal or adjustment of mounting members. In one aspect, the door catch can include a ball catch base, a threaded ball plunger assembly, a catch bumper, and a bumper base. In another aspect, the catch bumper and the bumper base can optionally be combined into a single catch bar bracket. The ball plunger assembly is adjustably mounted within a threaded aperture of ball catch base. A ball captive in one end of the ball plunger assembly engages a detent in the catch bumper, or catch bar bracket, providing friction to hold the door open. The position of the ball plunger assembly can be adjusted vertically to increase or decrease the tension between the detent and the ball plunger assembly.