Roll-Formed Bar Lock Assembly for Accessible Secure Closure
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Solution Overview
Problem
Conventional bar lock assemblies are heavy, costly to manufacture, and difficult to modify, with handles that are not easily accessible for securing, and they lack flexibility in accommodating locking devices.
Innovation Solution
The bar lock assembly is designed with a keeper and cam made from roll-formed sheet metal, featuring laterally spaced side walls and rotatable shafts, allowing for easy assembly and modification, and includes a U-shaped cam that can be nested within the keeper, enabling secure locking without needing to access the handle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If die-cast parts are used for keeper and cam, then strength and durability are improved, but weight increases and manufacturing cost increases
Solution Approach 1:
The patent changes the manufacturing parameters from die-cast to roll-formed sheet metal, fundamentally altering how the keeper and cam are produced. This parameter change enables weight reduction while maintaining structural integrity through optimized sheet metal forming techniques and geometric design.
Solution Approach 2:
The patent employs composite construction by combining roll-formed sheet metal components with strategic reinforcement elements. The U-shaped keeper and cam are formed from sheet metal and then reinforced with strategically placed strengthening features that provide durability without the weight of traditional die-cast materials.
2Strength
If die-cast parts are used for keeper and cam, then strength and durability are improved, but manufacturing cost increases
Solution Approach 1:
The patent changes the manufacturing parameters from die-cast to roll-formed sheet metal, fundamentally altering how the keeper and cam are produced. This parameter change enables weight reduction while maintaining structural integrity through optimized sheet metal forming techniques and geometric design.
Solution Approach 2:
The patent divides the locking mechanism into separate, modular components (keeper, cam, shafts, engagement members) that can be independently manufactured using roll-forming processes. This segmentation allows for more flexible manufacturing, easier assembly, and reduced tooling costs compared to monolithic die-cast parts.
3Stability of the object's composition
If conventional bar lock assembly is used, then structural integrity is maintained, but adaptability to accommodate locking devices is reduced
Solution Approach 1:
The patent designs the keeper and cam with universal features that can accommodate multiple locking device types. The U-shaped keeper with its open structure and the cam with its engagement members can interface with various shaft configurations and locking mechanisms, making the assembly adaptable to different applications while maintaining structural integrity.
Solution Approach 2:
The patent incorporates movable and adjustable components, including the rotatable cam and engagement members that can be positioned at different locations along the shaft. This dynamic design allows the locking mechanism to adapt to various shaft positions and locking device configurations while maintaining secure engagement.
4Device complexity
If handle is positioned at elevated location, then structural design is simplified, but accessibility for lock manipulation is reduced
Solution Approach 1:
The patent repositions the handle and lock manipulation interface from an elevated vertical location to a horizontal orientation at the end of the shaft. This dimensional change in handle positioning maintains structural simplicity while significantly improving accessibility, allowing users to easily reach and manipulate the lock from either side of the assembly.
Data Source
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AI summary
A bar lock assembly includes a keeper having a base and a pair of laterally spaced side walls extending transversely from the base. At least one shaft extends between and is coupled to the side walls. A cam is coupled to and rotatable relative to the keeper between an engaged position and a disengaged position. The cam includes an engagement member engaged with the shaft when rotated to the engaged position. The engagement member is disengaged with the first shaft when rotated to the disengaged position. The cam may include a pair of engagement members. The keeper and/or cam may be roll formed and configured with a U-shaped cross-section.