Molded Plastic Locker Latch Mechanism
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Solution Overview
Problem
Existing storage units, such as lockers, face issues with material waste, complex assembly, precise tolerances, high labor costs, and costly assembly and inspection due to their design and manufacturing processes.
Innovation Solution
A locker design featuring a molded plastic construction with a latch mechanism that uses a latch bar and actuator plate connected by rollers and diagonal ribs, allowing for easy assembly and reduced material usage, where the handle moves vertically to control the latch bar's horizontal movement, and incorporates a padlock mechanism for security.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional latch mechanisms are used with multiple parts and complex assembly, then the latch can provide secure locking, but the assembly complexity and labor costs increase significantly
Solution Approach 1:
The patent combines multiple latch mechanism components into a single integrated molded plastic housing. The housing incorporates the latch bar, actuator plate, rollers, and diagonal ribs as one unified part, eliminating the need for separate components and complex assembly operations while maintaining the secure locking function.
Solution Approach 2:
The molded plastic housing serves multiple functions simultaneously: it provides structural support, contains the latch mechanism, guides the latch bar movement through integrated slots, and provides the locking interface. This multi-functionality reduces the number of separate parts needed.
2Manufacturing precision
If traditional fabrication methods are used for latch mechanisms, then the components can be precisely manufactured, but material waste increases significantly
Solution Approach 1:
The patent consolidates multiple metal components into a single molded plastic housing, enabling production through injection molding or similar processes that minimize material waste compared to traditional metal fabrication and assembly methods.
Solution Approach 2:
The invention changes the material parameter from metal to molded plastic, which allows for more efficient manufacturing processes with lower material waste. The molded plastic can be formed directly into the complex three-dimensional shape with integrated features, reducing scrap and offcuts.
3Reliability
If restrictive tolerances and undue precision are required for latch mechanism assembly, then the locking function can be ensured, but the assembly time and skilled labor costs increase
Solution Approach 1:
By integrating the latch bar, actuator plate, rollers, and guiding features into a single molded housing, the patent eliminates multiple assembly steps and the need for skilled workers to precisely fit together separate components. The integrated design maintains functional reliability while dramatically reducing assembly time.
Solution Approach 2:
The molded housing is designed as a modular unit that can be easily attached to the door assembly, allowing for simple installation and replacement without requiring complex alignment or adjustment procedures.
4Adaptability or versatility
If multiple separate parts are used in the latch mechanism, then the components can be individually optimized, but the number of parts to assemble increases
Solution Approach 1:
The patent merges the latch bar, actuator plate, rollers, and housing into a single integrated component. This consolidation maintains the functional advantages of having specialized components while eliminating the complexity of assembling multiple separate parts.
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 reduces material waste, simplifies assembly, lowers production costs, and enhances ease of installation while maintaining security through a compact and efficient latch mechanism, allowing for comfortable handling and reduced friction.
Implementation Method 1
Each diagonal rib is positioned between a respective one pair of spaced rollers, such that when the actuator plate is moved vertically, each pair of rollers will move along the diagonal rib positioned between that pair of rollers causing the latch bar to move horizontally.
Data Source
AI summary
A locker has a latch bar attached to the inside surface of door by projections that extend through respective slots in the bar. The slots are configured to permit the bar to move parallel to the door between an extended position and a retracted position, the extended position being horizontally offset from the retracted position. An actuator plate is positioned between the inside surface of the door and the latch bar and is connected to a handle on the outside surface of the door. The at least one pair of spaced rollers is provided on the actuator plate. A diagonal rib is attached to the latch bar for each pair of rollers. Each diagonal rib is positioned between a respective pair of spaced apart rollers, such that when the handle and actuator plate are moved vertically, each pair of rollers will move along the diagonal rib positioned between that pair of rollers causing the latch bar to move horizontally. The handle preferably has an upper portion that is parallel to the front surface of the door and a lower hand grip portion that extends away from the upper portion.