Latchbolt Damper Module Using Dual Slowing Mechanisms for Noise Control

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Solution Overview

Problem

Conventional exit devices generate excessive noise due to the free return of the latchbolt and impact between components during latching and relatching operations, which is undesirable in quiet environments like healthcare settings.

Innovation Solution

A damper module is introduced, comprising a mounting bracket, a first slowing mechanism with a rack gear and rotary damper, and a second slowing mechanism with a slowing arm and biasing member, to independently slow the extension speed of the latchbolt, reducing noise generation during latching and relatching operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the latchbolt is allowed to return freely to its extended position, then the operation is simple and quick, but excessive noise is generated due to impact and grinding between components

Engineering Contradiction:
Improvelatchbolt operation simplicityVSAvoidnoise generation
Core Design Contradiction:
Ease of operationVSObject-generated harmful factors

Solution Approach 1:

A damper module is introduced as an intermediary component between the latchbolt mechanism and the external environment. The damper includes a piston moving within a cylinder filled with viscous fluid, creating resistance that slows the latchbolt's extension speed without adding complex mechanical linkages. This intermediary system reduces impact forces and grinding noises while maintaining operational simplicity.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent changes the velocity parameter of the latchbolt by introducing a controllable resistance force. The damper module adjusts the extension speed of the latchbolt from its original high-speed free return to a controlled, slower movement. By modifying the speed parameter through fluid resistance, the system reduces kinetic energy at the point of contact, thereby minimizing impact noise and component grinding.

Inventive Principle:
Principle #35Parameter changes

2Object-generated harmful factors

If the latchbolt extension speed is reduced to minimize noise, then noise levels decrease, but the operation time increases

Engineering Contradiction:
Improvenoise levelsVSAvoidoperation time
Core Design Contradiction:
Object-generated harmful factorsVSLoss of time

Solution Approach 1:

The damper module applies resistance selectively during specific phases of latchbolt operation. The viscous fluid resistance is not uniformly applied throughout the entire movement range but is concentrated during the critical extension phase where noise generation occurs. This localized application of damping force reduces noise during the harmful impact phase while minimizing impact on overall operation time.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The damper provides sufficient resistance during the latchbolt extension phase to achieve noise reduction, but does not overly restrict the movement. The viscous fluid allows controlled passage of the piston during normal operation, providing just enough damping to reduce impact noise without creating excessive friction that would significantly delay the latching operation.

Inventive Principle:
Principle #16Partial or excessive action

3Device complexity

If conventional exit devices are used, then the device complexity is low, but noise exceeds maximum recommended levels in quiet environments

Engineering Contradiction:
Improvedevice structure simplicityVSAvoidnoise exceeding guidelines
Core Design Contradiction:
Device complexityVSObject-generated harmful factors

Solution Approach 1:

The damper module is designed as a compact, nested structure where the piston fits within a cylinder, and the entire assembly integrates into the existing latchbolt mechanism. The damper components are housed within a confined space, with the piston rod connecting directly to the latchbolt assembly. This nested design adds noise reduction functionality while minimizing increases in overall device complexity and footprint.

Inventive Principle:
Principle #7Nested doll (Nesting)

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 damper module effectively reduces noise by slowing the deactuating and extending speeds of the latchbolt and retractor, minimizing vibrations and metal-to-metal contact noises, thereby enhancing the quiet operation of exit devices.

Implementation Method 1

a rotary damper including a pinion gear

Methodology Applied
Scientific EffectViscous damping: Viscous Damping

Implementation Method 2

a second slowing mechanism includes a slowing arm and a biasing member engaged with the slowing arm

Methodology Applied
Scientific EffectElastic potential energy: Spring

Data Source

PatentUS11156025B2Latchbolt damping module
Publication Date: 2021.10.26 SCHLAGE LOCK CO LLC
  • US11156025B2 patent drawing
  • US11156025B2 patent drawing
  • US11156025B2 patent drawing

AI summary

An exemplary damper module is configured for use with a latchbolt assembly, and generally includes a mounting bracket, a first slowing mechanism, and a second slowing mechanism. The latchbolt assembly generally includes a drive member, a latchbolt, and a retractor connected between the drive member and the latchbolt. Each of the slowing mechanisms is independently operable to slow the extension speed of the latchbolt. The first slowing mechanism includes a rack gear and a rotary damper including a pinion gear. The rack gear is configured to be mounted to the drive member, and the rotary damper is mounted to the mounting bracket. The second slowing mechanism includes a slowing arm and a biasing member engaged with the slowing arm. The slowing arm is movably mounted to the mounting bracket and is configured to engage the retractor.