Padlock shackle shroud arrangements

Abstract

A padlock assembly includes a padlock and a shackle shroud. The padlock includes a lock body defining first and second shackle bores extending to first and second shackle openings in a first end of the lock body, and a shackle having first and second axially extending shackle legs receivable in the shackle bores of the lock body, the shackle being moveable in an axial direction between retracted and extended positions, with at least one of the first and second shackle legs being withdrawn from the lock body in the extended position. The shackle shroud includes a shroud member having a base portion secured to the first end of the lock body and a first wall portion extending axially from the base portion and laterally outward of the first shackle leg, and at least a first reinforcing insert disposed in a first axially extending cavity in the first wall portion.

Description

PADLOCK SHACKLE SHROUD ARRANGEMENTSCross-Reference to Related Application

[0001] This application claims priority to and all benefit of U.S. Provisional Patent Application Serial No. 63 / 718,018, filed on November 8, 2024 and entitled PADLOCK SHACKLE SHROUD ARRANGEMENTS, the entire disclosure of which is incorporated by reference herein.Background

[0002] Padlocks are used in a variety of applications, including, for example, with enclosures such as lockers, storage sheds, and various gates and doors. A typical padlock includes a generally rectangular lock body having a generally U-shaped shackle extending from one end of the lock body, and a locking mechanism disposed in the lock body securing retention of the shackle ends within the lock body. When a lock interface (e.g., keyway of a lock cylinder, one or more combinations dials) is manipulated to move the locking mechanism to an unlocked or shackle releasing condition, the shackle is slideable out of the lock body to remove or separate either or both legs of the shackle from the lock body, allowing removal of the lock from a hasp or other such portion of an enclosure to be locked.

[0003] A padlock shackle is commonly provided in a hard, cut-resistant material (e.g., boron alloy or hardened steel) to deter efforts to cut the shackle for unauthorized access to the locked structure. However, heavy cutting tools such as angle grinders and hydraulic bolt cutters may still cut through a locked shackle relatively quickly.Summary

[0004] In an exemplary embodiment of the present disclosure, a padlock assembly includes a padlock and a shackle shroud. The padlock includes a lock body defining first and second shackle bores extending to first and second shackle openings in a first end of the lockbody, and a shackle having first and second axially extending shackle legs receivable in the shackle bores of the lock body, the shackle being moveable in an axial direction between retracted and extended positions, with at least one of the first and second shackle legs being withdrawn from the lock body in the extended position. The shackle shroud includes a shroud member having a base portion secured to the first end of the lock body and a first wall portion extending axially from the base portion and laterally outward of the first shackle leg, and at least a first reinforcing insert disposed in a first axially extending cavity in the first wall portion.

[0005] In another exemplary embodiment of the present disclosure, a shackle shroud is provided for a padlock having a lock body defining first and second shackle bores extending to first and second shackle openings in a first end of the lock body and a shackle having first and second axially extending shackle legs receivable in the first and second shackle bores of the lock body, the shackle being moveable in an axial direction between a retracted position and an extended position, with at least one of the first and second shackle legs being withdrawn from the lock body in the extended position. The shackle shroud includes a shroud member having a base portion securable to the first end of the lock body and a first wall portion extending axially from the base portion to be positioned laterally outward of the first shackle leg when the shroud member is secured to the first end of the lock body. At least a first reinforcing insert is disposed in a first axially extending cavity in the first wall portion.

[0006] In another exemplary embodiment of the present disclosure, a locking system includes a padlock, a hasp unit, and a shackle shroud. The padlock includes a lock body and a shackle having first and second shackle legs extending axially from a first end of the lock body and joined by a bight portion of the shackle. The hasp unit includes a mounting portion and a loop portion extending from the mounting portion and defining an aperture sized to receive the bight portion of the shackle and having a thickness sized to be received between the first and second shackle legs. The shackle shroud includes a shroud member having a base portion securable to the first end of the lock body and first and second wall portions extending axially from the base portion. The first and second wall portions have corresponding first and second rear wall portions spaced apart by a first lateral dimension sized to receive the first and second shackle legs therebetween when the shroud member is secured to the first end of the lock body, and corresponding first and second front wall portions spaced apart by a second lateral dimension smaller than the first lateral dimension and sized to be substantially spanned by aforward portion of the loop portion when the shroud member is secured to the first end of the lock body and the padlock shackle is installed through the loop portion, thereby blocking access to the shackle bight portion by a cutting tool.

[0007] In another exemplary embodiment of the present disclosure, a locking system includes a padlock, a hasp unit, and a shackle shroud. The padlock includes a lock body and a shackle having first and second shackle legs extending axially from a first end of the lock body and joined by a bight portion of the shackle. The hasp unit includes a mounting portion and a loop portion extending from the mounting portion and defining an aperture sized to receive the bight portion of the shackle and having a thickness sized to be received between the first and second shackle legs. The shackle shroud includes a shroud member having a base portion securable to the first end of the lock body and first and second wall portions extending axially from the base portion to receive the first and second shackle legs therebetween when the shroud member is secured to the first end of the lock body. The first and second wall portions further include an upper portion shaped to prevent forward pivoting movement of the lock body about the bight portion beyond a pivot angle of about 120 degrees, or beyond a pivot angle of about 90 degrees, when the shroud member is secured to the first end of the lock body and the padlock shackle is installed through the loop portion.Brief Description of the Drawings

[0008] Further features and advantages will become apparent from the following detailed description made with reference to the accompanying drawings, wherein:

[0009] FIG. 1 is a front perspective view of a conventional padlock;

[0010] FIG. 2 is a front perspective view of a padlock assembly including the padlock of FIG. 1 and a shackle shroud in accordance with an exemplary embodiment of the present disclosure;

[0011] FIG. 3 is a rear perspective view of the padlock assembly of FIG. 2;

[0012] FIG. 4 is a partial cross-sectional rear view of the padlock assembly of FIG. 2;

[0013] FIG. 5 is an upper rear perspective view of the shackle shroud of the padlock assembly of FIG. 2;

[0014] FIG. 6 is a lower perspective view of the shackle shroud of FIG. 5;

[0015] FIG. 7 is a partial cross-sectional view of a padlock assembly including a shackle shroud, in accordance with another exemplary embodiment of the present disclosure;

[0016] FIG. 8 is an upper rear perspective view of another shackle shroud for a padlock assembly in accordance with another exemplary embodiment of the present disclosure;

[0017] FIG. 9 is a lower perspective view of the shackle shroud of FIG. 7;

[0018] FIG. 10 is an upper rear perspective view of another shackle shroud for a padlock assembly in accordance with another exemplary embodiment of the present disclosure;

[0019] FIG. 11 is a lower perspective view of the shackle shroud of FIG. 10;

[0020] FIG. 12 is a rear cross-sectional view of a padlock assembly including the shackle shroud of FIG. 10;

[0021] FIG. 13 is an upper rear perspective view of another shackle shroud for a padlock assembly in accordance with another exemplary embodiment of the present disclosure;

[0022] FIG. 14 is a lower perspective view of the shackle shroud of FIG. 13;

[0023] FIG. 15 is a front cross-sectional view of a padlock assembly including the shackle shroud of FIG. 13;

[0024] FIG. 16 is a cross-sectional view of a padlock assembly including a shackle shroud, in accordance with another exemplary embodiment of the present disclosure;

[0025] FIG. 17 is an exploded perspective view of the shackle shroud of the padlock assembly of FIG. 16;

[0026] FIG. 18 is a front view of a locking system including a hasp unit, a padlock, and a shackle shroud, in accordance with another exemplary embodiment of the present disclosure;

[0027] FIG. 19 is an upper perspective view of the locking system of FIG. 18;

[0028] FIG. 20 is a side view of the locking system of FIG. 18;

[0029] FIG. 21 is a side view of the locking system of FIG. 18, shown with the padlock pivoted forward to a position limited by the shackle shroud;

[0030] FIG. 22 is a schematic front view of a padlock assembly including a shackle shroud, in accordance with another exemplary embodiment of the present disclosure;

[0031] FIG. 23A is a schematic front view of a padlock assembly including a shackle shroud shown in a raised, shackle protecting position, in accordance with another exemplary embodiment of the present disclosure; and

[0032] FIG. 23B is a schematic front view of the padlock assembly of FIG. 23 A, with the shackle shroud shown in a lowered, shackle exposing position.Detailed Description

[0033] This Detailed Description merely describes exemplary embodiments and is not intended to limit the scope of the claims in any way. Indeed, the invention as claimed is broader than and unlimited by the exemplary embodiments, and the terms used in the claims have their full ordinary meaning.

[0034] While various aspects, concepts and features of the inventions may be described and illustrated herein as embodied in combination in the exemplary embodiments, these various aspects, concepts and features may be used in many alternative embodiments, either individually or in various combinations and sub-combinations thereof. Unless expressly excluded herein all such combinations and sub-combinations are intended to be within the scope of the present inventions. Still further, while various alternative embodiments as to the various aspects, concepts and features of the inventions— such as alternative materials, structures, configurations, methods, devices and components, alternatives as to form, fit and function, and so on— may be described herein, such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether presently known or later developed. Those skilled in the art may readily adopt one or more of the aspects, concepts or features into additional embodiments and uses within the scope of the present inventions even if such embodiments are not expressly disclosed herein. Additionally, even though some features, concepts or aspects of the inventions may be described herein as being a preferred arrangement or method, such description is not intended to suggest that such feature is required or necessary unless expressly so stated. Still further, exemplary or representative values and ranges may be included to assist in understanding the present disclosure; however, such values and ranges are not to be construed in a limiting sense and are intended to be critical values or ranges only if so expressly stated. Parameters identified as “approximate” or “about” a specified value are intended to include both the specified value, values within 5% of the specified value, and values within 10% of the specified value, unless expressly stated otherwise. Further, it is to be understood that the drawings accompanying the present disclosure may, but need not, be to scale, and therefore may be understood as teaching various ratios andproportions evident in the drawings. Moreover, while various aspects, features and concepts may be expressly identified herein as being inventive or forming part of an invention, such identification is not intended to be exclusive, but rather there may be aspects, concepts and features that are fully described herein without being expressly identified as such or as part of a specific invention. Descriptions of exemplary methods or processes are not limited to inclusion of all steps as being required in all cases, nor is the order that the steps are presented to be construed as required or necessary unless expressly so stated.

[0035] An exemplary padlock 110, illustrated in FIG. 1, includes a lock body 120 with first and second shackle bores 137, 138 extending to a first end or upper end 121 of the lock body and retaining first and second legs 157, 158 of a generally U-shaped shackle 150. The illustrated padlock includes an electronic keypad lock interface 140 operable to move an internal locking mechanism (e.g., rotatable blocker and locking balls which engage notches in the shackle legs 157, 158) from a locked position securing the shackle 150 in a retracted or closed position to an unlocked position permitting axial movement of the shackle to an extended or open position in which the shorter second shackle leg 158 is withdrawn from the lock body 120 to permit removal of the padlock from a secured structure (e.g., gate, hasp). In other embodiments (not shown), other lock interfaces may be used, such as, for example, combination dials or a key operated lock cylinder.

[0036] To protect the straight, axially extending leg portions 157, 158 of the shackle 150, considered more vulnerable to attack by cutting tools (e.g., bolt cutters, hacksaws, angle grinders) as compared to the curved, U-bend portion of the shackle, a shackle shroud may be assembled with the first end of the lock body, with axially extending wall portions laterally outward of the first and second shackle legs. FIGS 2 - 4 illustrate the padlock 110 of FIG. 1 with a shackle shroud 160 assembled with the first end of the lock body 120 to form a shrouded padlock assembly 101. The exemplary shackle shroud 160 includes a shroud body or shroud member 161 having a base portion 162 secured to the first end 121 of the lock body 120, with one or more openings 162a, 162b through which the shackle legs 157, 158 extend. An axially extending first wall portion 163 extends from the base portion laterally outward of the first shackle leg 157, and an axially extending second wall portion 164 extends from the base portion, laterally outward of the second shackle leg 158. The axially extending first and second wall portions 163, 164 of the shackle shroud 160 block cutting tool access to the shackle legs157, 158. The shroud member 161 may be provided in a relatively hard, cut resistant material (e.g., tungsten carbide, boron carbide, ceramic composite (e.g., alumina, zirconia), titanium alloys, maraging steel) to further impede cutting tool attacks to the shackle.

[0037] The shroud member 161 may be shaped to provide clearance for the short shackle leg 158 to be pivoted away from the lock body 120 when the shackle 150 is moved to the withdrawn or open position to permit removal of the padlock assembly 101 from the secured structure. As shown in FIG. 3, the shroud member 161 may include a cutout 162c in the base portion 162 and an open side 164a of the second wall portion 164 to provide clearance for pivoting movement of the withdrawn short shackle leg 158.

[0038] In some embodiments, the shroud member may be secured with the first end of the padlock body merely by installation of the shackle through openings in the shroud member base, with the shackle blocking movement of the shroud member away from the lock body. In other embodiments, the shroud member may be temporarily or permanently fastened or otherwise secured to the lock body. In the illustrated embodiment of FIGS. 2 - 4, the base portion 162 of the shroud member 161 includes a fastener hole 162d that aligns with a corresponding fastener hole 122 in the lock body first end 121 for installation of a mounting fastener (e.g., screw or bolt, not shown) to rigidly and securely attach the shackle shroud 160 to the lock body 120. When the shackle is in the closed or retracted position, access to the mounting fastener may be effectively impeded.

[0039] According to an exemplary aspect of the present disclosure, a shackle shroud may be provided with one or more inserts (e.g., plates, bars, rods) of a hard, cut resistant material disposed in corresponding cavities in the shackle covering wall portions of the shroud member. The inserts may be provided in a harder or more cut resistant material than the shroud member, thereby providing additional cut resistance reinforcement for the exposed portions of the straight shackle legs, which may be more vulnerable to attack by bolt cutters, angle grinders, or other cutting tools, while allowing for use of these harder materials in smaller and / or more easily manufactured components, such as plates, bars, or rods. In some embodiments, the insert may be provided in a material having a high hardness and a relatively low fracture resistance (e.g., ceramic), as the enclosure of the insert may protect the material from fracture. As one example, the shroud member may be manufactured from die cast, extrusion, CNC machining, having a hardness of no less than HRC40, while the inserts may be manufactured from sintering,having a hardness of HRC45 - 65. In some embodiments, the insert may be provided in a material having a high hardness and a relatively low fracture resistance (e.g., ceramic), as the enclosure of the insert may protect the material from fracture. Exemplary insert materials include, for example, tungsten carbide, boron carbide, ceramic composites (e.g., alumina, zirconia), titanium alloys, maraging steel, graphene ceramic composite materials and graphene metallic carbide composite materials. Exemplary ceramic composite materials and graphene metallic carbide composite materials are disclosed in U.S. Patent Application Pub. No. 2023 / 0374633, the entire disclosure of which is incorporated herein by reference, and are manufactured under the name Ferosafe by Tenmat Limited of Manchester, England.

[0040] In the illustrated embodiment of FIGS. 2 - 6, a first reinforcing insert (e.g., plate) 167 is disposed in a first axially extending cavity 165 in the first wall portion 163, and a second reinforcing insert (e.g., plate) 168 is disposed in a second axially extending cavity 166 in the second wall portion 164. As shown in FIG. 4, the reinforcing inserts 167, 168 may extend substantially the entire axial length from the lock body first end 121 to the curved, U-bend or bight portion 159 of the shackle 150 to provide cut resistance reinforcement for the exposed portions of the straight shackle legs 157, 158.

[0041] The reinforcing inserts 167, 168 may be secured within the shroud member wall cavities 165, 166 using a variety of arrangements, such as, for example, adhesives, ultrasonic welding, and / or brazing. In other embodiments, the shroud member may be molded over the inserts using, for example, suitable insert molding or overmolding processes.

[0042] In the illustrated embodiment, the shroud member wall cavities 165, 166 extend an entire axial length of the first and second wall portions 163, 164. In other embodiments, as shown, for example, in FIG. 7, the cavities 165', 166' may form closed ended pockets in the shackle covering wall portions 163', 164', for example, so that the reinforcing inserts 167', 168' are not exposed on an upper surface of the shroud member 161 '. In still other embodiments, as shown, for example, in FIG. 15, the cavities may form inwardly open recesses or channels within the shackle covering wall portions, thereby eliminating the use of a through bore or blind bore in the wall portion, with the reinforcing insert secured (e.g., by adhesive, welding, brazing, etc.) to one or more of the recessed channel surfaces in contact with the reinforcing insert.

[0043] FIGS. 8 - 9 illustrate another exemplary shackle shroud 260, similar to theshackle shroud 160 of FIGS. 2 - 6 but including a base portion 262 of the shroud member 261 having an outer wall portion 262d with inner nubs 262e providing for press fit retention of the shackle shroud 260 on the first end of the lock body. In other embodiments, other securing arrangements (e.g., one or more mounting fasteners, as shown in the embodiments of FIGS. 2 - 6 and 10 - 15) may additionally be used.

[0044] In the embodiments of FIGS. 2 - 9, the reinforcing inserts 167, 168, 267, 268 extend substantially parallel to the shackle legs to provide enhanced cut resistance along the exposed portions of the straight shackle legs. In other embodiments, the reinforcing inserts may include an upper portion disposed at a first, smaller lateral distance from the shackle legs, and a lower portion disposed at a second, larger lateral distance from the shackle legs and extending beyond a junction between the exposed portions of the shackle legs and the lock body, a potential point of vulnerability for a cutting tool attack.

[0045] FIGS. 10 - 12 illustrate another exemplary shackle shroud 360 including a shroud member 361 having a base portion 362 securable to a first end 321 of a lock body 320 (FIG. 12), and having openings 362a, 362b through which the shackle legs 357, 358 extend. An axially extending first wall portion 363 extends from the base portion laterally outward of the first shackle leg 357, and an axially extending second wall portion 364 extends from the base portion, laterally outward of the second shackle leg 358. The shroud member 361 may be shaped to provide clearance for the short shackle leg 358 to be pivoted away from the lock body 320 when the shackle 350 is moved to the withdrawn or open position to permit removal of the padlock assembly 301 from the secured structure. As shown in FIG. 10, the shroud member 361 may include a cutout 362c in the base portion 362 and an open side 364a of the second wall portion 364 to provide clearance for pivoting movement of the withdrawn short shackle leg 358.

[0046] In the illustrated embodiment of FIGS. 10 - 12, the base portion 362 of the shroud member 361 includes an apertured rear flange tab 362d that aligns with a corresponding fastener hole (not shown) in the lock body rear surface for installation of a mounting fastener (e.g., screw or bolt, not shown) to rigidly and securely attach the shackle shroud 360 to the lock body 320. As shown, the base portion of the shackle shroud may additionally or alternatively include a fastener hole 362e that aligns with a corresponding fastener hole 322 in the lock body first end 321 for installation of a mounting fastener (e.g., screw or bolt, not shown) to rigidlyand securely attach the shackle shroud 360 to the lock body 320. When the shackle is in the closed or retracted position, access to the mounting fastener may be effectively impeded. Other securing arrangements (e.g., nubs for press-fit retention on the padlock body, similar to the embodiment of FIGS. 7 - 9) may additionally or alternatively be used.

[0047] In the illustrated embodiment of FIGS. 10 - 12, a first reinforcing insert (e.g., plate) 367 is disposed in a first axially extending cavity 365 in the first wall portion 363, and a second reinforcing insert (e.g., plate) 368 is disposed in a second axially extending cavity 366 in the second wall portion 364. As shown in FIG. 12, the cavities 365, 366 and the retained reinforcing inserts 367, 368 may taper laterally inward from the shroud member base portion 362, such that upper portions of the reinforcing inserts are disposed at a first, smaller lateral distance from the shackle legs 357, 358 (FIG. 12), and lower portions of the reinforcing inserts are disposed at a second, larger distance from the shackle legs, allowing these lower portions to extend laterally outward of and beyond a junction between the exposed portions of the shackle legs and the lock body 320.

[0048] The reinforcing inserts 367, 368 may be secured within the shroud member wall cavities 365, 366 using a variety of arrangements, such as, for example, adhesives, welding (e.g., ultrasonic welding), and / or brazing. In other embodiments, the shroud member may be molded over the inserts using, for example, suitable insert molding or overmolding processes.

[0049] In the illustrated embodiment, the shroud member wall cavities 365, 366 form closed ended pockets in the shackle covering wall portions 363, 364, for example, so that the reinforcing inserts are not exposed on an upper surface of the shroud member 361. In other embodiments, the cavities may extend an entire axial length of the first and second wall portions, for example, for ease of manufacturing and assembly.

[0050] FIGS. 13 - 15 illustrate another exemplary shackle shroud 460 including a shroud member 461 having a base portion 462 securable to a first end 421 of a lock body 420 (FIG. 15), and having openings 462a, 462b through which the shackle legs 457, 458 extend. An axially extending first wall portion 463 extends from the base portion laterally outward of the first shackle leg 457, and an axially extending second wall portion 464 extends from the base portion, laterally outward of the second shackle leg 458. The shroud member 461 may be shaped to provide clearance for the short shackle leg 458 to be pivoted away from the lock body 420 when the shackle 450 is moved to the withdrawn or open position to permit removal of thepadlock assembly 401 from the secured structure. As shown in FIG. 14, the shroud member 461 may include a cutout 462c in the base portion 462 and an open side 464a of the second wall portion 464 to provide clearance for pivoting movement of the withdrawn short shackle leg 458.

[0051] In the illustrated embodiment of FIGS. 13 - 15, the base portion 462 of the shroud member 461 includes an apertured rear flange tab 462d that aligns with a corresponding fastener hole (not shown) in the lock body rear surface for installation of a mounting fastener (e.g., screw or bolt, not shown) to rigidly and securely attach the shackle shroud 460 to the lock body 420. Other securing arrangements (e.g., axially extending fastener holes in the shroud member base portion and lock body first end, similar to the embodiments of FIGS. 2 - 6 and 10 - 12, and / or nubs for press-fit retention on the padlock body, similar to the embodiment of FIGS. 7 - 9) may additionally or alternatively be used.

[0052] In the illustrated embodiment of FIGS. 13 - 15, an upper first reinforcing insert (e.g., plate) 467-1 is disposed in a first axially extending upper cavity 465-1 in the first wall portion 463, and an upper second reinforcing insert (e.g., plate) 468-1 is disposed in a second axially extending upper cavity 466-1 in the second wall portion 464, with the upper cavities and retained upper inserts being disposed at a first, smaller lateral distance from the shackle legs 457, 458 (FIG. 15). A lower first reinforcing insert (e.g., plate) 467-2 is disposed in a first axially extending lower cavity 465-2 in the first wall portion 463, and a lower second reinforcing insert (e.g., plate) 468-2 is disposed in a second axially extending lower cavity 466- 2 in the second wall portion 464, with the lower cavities and retained lower inserts being disposed at a second, larger lateral distance from the shackle legs 457, 458, such that the lower inserts extend laterally outward of and beyond a junction between the exposed portions of the shackle legs and the lock body 420. As shown, the shroud member wall portions 463, 464 may extend below the base portion 462 to provide additional reinforced coverage of the shackle / lock body junctions and the upper portion of the lock body 420.

[0053] The reinforcing inserts 467-1, 467-2, 468-1, 468-2 may be secured within the shroud member wall cavities 465-1, 465-2, 466-1, 466-2 using a variety of arrangements, such as, for example, adhesives, welding (e.g., ultrasonic welding), and / or brazing. In other embodiments, the shroud member may be molded over the inserts using, for example, suitable insert molding or overmolding processes.

[0054] In the illustrated embodiment, the shroud member upper cavities 465-1, 466-1 form closed ended pockets in the shackle covering wall portions 463, 464, for example, so that the reinforcing inserts are not exposed on an upper surface of the shroud member 461. In other embodiments, the cavities may extend to the upper surface of the shroud member, for ease of manufacturing and assembly.

[0055] In the illustrated embodiment, the shroud member lower cavities 465-2, 466-2 form inwardly open channels in the shackle covering wall portions 463, 464, thereby eliminating the use of a through bore or blind bore in the lower wall portion, with the reinforcing insert secured (e.g., by adhesive, welding, brazing, etc.) to one or more of the recessed channel surfaces in contact with the reinforcing insert. In other embodiments, the lower cavities may form through bores in the wall portions and base portion of the shroud member.

[0056] In the embodiments of FIGS. 2 - 15, the reinforcing inserts extend into an open lower end portion of the shroud member cavities, in the lower outer wall portion of the shroud member base portion. In other embodiments, the reinforcing inserts may be secured in the shroud member cavities by one or more cartridge elements installed in the shroud member base portion, for example, to more securely retain the reinforcing inserts in the shroud member, and / or to position the reinforcing inserts in the first and / or second wall portions of the shroud member, and above the base portion (for which additional reinforcement may be unnecessary).

[0057] FIGS. 16-17 illustrate another exemplary shackle shroud 560 including first and second cartridge elements 581, 582 installed in a shroud member 561 to position and retain first and second reinforcing inserts 567, 568 in the shroud member 561.

[0058] The shroud member includes a base portion 562 securable to a first end 521 of a lock body 520 of a padlock 510 (FIG. 16), and having openings 562a, 562b through which the shackle legs 557, 558 extend. An axially extending first wall portion 563 extends from the base portion 562 laterally outward of the first shackle leg 557, and an axially extending second wall portion 564 extends from the base portion, laterally outward of the second shackle leg 558. The shroud member 561 may be shaped to provide clearance for the short shackle leg 558 to be pivoted away from the lock body 520 when the shackle 550 is moved to the withdrawn or open position to permit removal of the padlock assembly 501 from the secured structure. As shown in FIG. 17, the shroud member 561 may include a cutout 562c in the base portion 562 and an open side 564a of the second wall portion 564 to provide clearance for pivoting movement ofthe withdrawn short shackle leg 558.

[0059] The shroud member 561 includes axially extending cavities 565, 566 defining upper channels 565a, 566a receiving the first and second reinforcing inserts 567, 568, and lower recesses 565b, 566b receiving and retaining the first and second cartridge elements 581, 582. The cartridge elements 581, 582 include upper cavities 583, 584 receiving lower portions of the reinforcing inserts 567, 568 to hold the reinforcing inserts in the upper channels 565a, 566a. The cartridge elements 581, 582 may be secured in the lower recesses 565b, 566b using a variety of arrangements, including, for example, adhesive, welding, fasteners, and / or press / interference fit engagement. As shown in FIG. 17, the cartridge elements 581, 582 may include one or more deformable tabs or detents 585, 586 that engage the shroud member lower recesses 565b, 566b to facilitate interference fit engagement. While the cartridge elements 581, 582 may be provided in the same material as the shroud member 561 (e.g., a cut-resistant material, such as tungsten carbide, boron carbide, ceramic composite (e.g., alumina, zirconia), titanium alloys, maraging steel), in other embodiments, the cartridge elements may be provided in a material having a lesser hardness or cut resistance (e.g., plastic), for example, to improve press / interference fit retention and / or to use a lower cost material in a less critical portion of the shackle shroud 560.

[0060] The reinforcing inserts 567, 568 may be loosely received in the upper channels 565a, 565b, while still being securely retained by the cartridge elements 581, 582. Alternatively, the reinforcing inserts 567, 568 may be more fixedly secured in the upper channels 565a, 565b, for example, by press / interference fit, adhesive, and / or welding / brazing.

[0061] In the illustrated embodiment of FIGS. 16-17, the shroud member 561 includes a base portion 562 having an outer wall portion 562d with inner nubs 562e providing for press fit retention of the shackle shroud 260 on the first end of the lock body. In other embodiments, other securing arrangements (e.g., one or more mounting fasteners, as shown in the embodiments of FIGS. 2 - 6 and 10 - 15) may additionally or alternatively be used.

[0062] In other embodiments, other reinforced shackle shroud configurations may be utilized. For example, a shackle shroud may be configured to include a reinforcing insert in only one of the shackle covering wall portions to provide enhanced cut resistance for only one of the shackle legs (e g., the long shackle leg). As another example, a shackle shroud may include only one shackle covering wall portion (e.g., for the long shackle leg), with a reinforcinginsert disposed in the single shackle covering wall portion. Such arrangements may be suitable, for example, in assemblies for which making two cuts in a single shackle leg would be otherwise impeded (e.g., due to a short shackle length).

[0063] According to another exemplary aspect of the present disclosure, a shackle shroud may additionally or alternatively be shaped or dimensioned to limit or prevent cutting / grinding tool access to the padlock shackle when the padlock shackle is secured through a substrate mounted hasp and the shackle shroud is assembled with the padlock. For example, a shroud member of a shackle shroud may include first and second shackle covering wall portions (e.g., similar to the wall portions of the embodiments of FIGS. 2 - 17) further provided with corresponding first and second front wall portions spaced apart by a reduced lateral dimension minimizing cutting / grinding tool access to the bight portion of the shackle between the first and second front wall portions.

[0064] In an exemplary locking system 600, as illustrated in FIGS. 18-21, a padlock 610 assembled with a shackle shroud 660 is used with a hasp unit 690 including a mounting portion 691 (e.g., one or more plates, flanges, etc.) mountable to a substrate of a secured structure S (e.g., gate, door, etc.) and a loop portion 692 (e.g., one or more rings, apertured tabs, U-shaped loops, etc.) extending from the mounting portion and defining an aperture 693 sized to receive the bight portion 659 of the padlock shackle 650, and having a thickness t sized to be received between the first and second shackle legs 657, 658. When the padlock shackle 650 is secured through the loop portion 692 of the hasp unit 690, movement of the secured structure S is prevented, for example, by blocking withdrawal of the loop portion from a slotted plate 695 (FIG. 18), or by blocking separation of multiple loop elements of the hasp unit.

[0065] While the hasp unit may be mounted in a variety of orientations, in some arrangements, the hasp unit is mounted such that an end or forward portion 694 (e.g., distal to the mounting portion) of the loop portion 692 extends or is oriented substantially vertically, with the bight portion 659 of the secured padlock shackle 650 extending substantially horizontally through the loop portion aperture 693, so that the padlock body 620 hangs downward in a substantially vertical orientation (e.g., may tilt forward due to abutment of the shroud rear surface with the substrate or hasp mounting portion). Alternatively, the hasp unit 690 may be mounted such that the forward portion 694 of the loop portion 692 extends substantially horizontally, with the bight portion 659 of the secured padlock shackle 650extending substantially vertically through the loop portion aperture 693, so that the padlock body 620 extends sideways in a substantially horizontal orientation (e.g., may slightly tilt or lean downward due to gravity).

[0066] The exemplary shackle shroud 660 includes a shroud member 661 having abase portion 662 secured to the first end 621 of the lock body 620, with openings 662a, 662b (FIG. 19A) through which the shackle legs 657, 658 extend. An axially extending first wall portion 663 extends from the base portion 662 laterally outward of the first shackle leg 657, and an axially extending second wall portion 664 extends from the base portion, laterally outward of the second shackle leg 658, blocking cutting tool access to the shackle legs 657, 658. The first and second wall portions 663, 664 include corresponding first and second rear wall portions 671 , 672 spaced apart by a first lateral dimension L 1 sized to receive the first and second shackle legs 657, 658 therebetween, and corresponding first and second front wall portions 673, 674 spaced apart by a second lateral dimension L2 smaller than the first lateral dimension and sized to be substantially (e.g., at least about 75%) spanned by a forward portion 694 of the loop portion 692, thereby substantially blocking access to the shackle bight portion 659, for example, by a cutting or grinding tool.

[0067] The second lateral dimension L2 between the front wall portions 673, 674 may be sized, for example, to be no more than about 30% greater than the hasp loop portion thickness t, to minimize the portion of the shackle bight portion 659 exposed between the hasp loop portion 692 and the front wall portions. In some embodiments, the difference between the second lateral dimension L2 and the hasp loop portion thickness t is less than or substantially equal to the thickness of a conventional cutting or grinding wheel blade (e.g., 1 / 16 inch to % inch) to effectively block access to the shackle bight portion by a corresponding cutting tool. In other embodiments, the second lateral dimension L2 is smaller than the hasp loop portion thickness t, such that the second lateral dimension is fully spanned or taken up by the forward portion 694 of the hasp loop portion 692.

[0068] The shroud member 661 may be shaped to provide clearance for the short shackle leg 658 to be pivoted away from the lock body 620 when the shackle 650 is moved to the withdrawn or open position to permit removal of the padlock assembly 601 from the secured structure. As shown in FIG. 19A, the rear wall portion 672 of the second wall portion 664 may be shaped to provide clearance for pivoting movement of the withdrawn short shackle leg 658,while the rear wall portion 671 of the first wall portion 663 may include an inward lip portion 671a to more closely receive and retain the long shackle leg 657. As shown, the first and second wall portions 663, 664 may include medial wall portions 675, 676 between the front wall portions 673, 674 and the rear wall portions 671, 672, that are spaced apart by a third lateral dimension L3 smaller than the first lateral dimension LI and larger than the second lateral dimension L2, for example, to engage the front surfaces of the shackle legs 657, 658, and / or to receive the front portion 694 of the hasp loop portion 692.

[0069] The first and second wall portions of a shackle shroud member may additionally or alternatively be shaped and sized to further block attacks to the shackle. For example, as shown, upper portions 673a, 674a the first and second front wall portions 673, 674 may extend beyond the bight portion 659 of the padlock shackle 650, for example to further minimize the front side exposed portion(s) of the shackle.

[0070] As another example, the upper portions 673a, 674a the first and second front wall portions 673, 674 may be sized and shaped to prevent forward pivoting movement of the lock body 620 about the shackle bight portion 659 beyond a pivot angle a to limit exposure of and / or access to the rear side of the shackle, for which coverage of the shackle by the shroud member is more limited. For example, the pivot angle a may be less than about 120 degrees, or up to about 90 degrees. As shown in FIG. 21, when the hasp unit 690 is mounted such that the loop portion 692 extends or is oriented substantially vertically, so that the padlock body 520 hangs downward in a substantially vertical orientation, the upper front portions 673a, 674a of the shroud member wall portions 663, 664 may contact the hasp unit mounting portion 691, to prevent forward pivoting movement of the lock body 620 about the shackle bight portion 659 beyond a substantially horizontal orientation of the lock body (i.e., about a 90 degree pivot angle a).

[0071] As another example, an upper surface 663a, 664a of the first and second wall portions 663, 664 may extend axially outward from the rear wall portions 671, 672 to the front wall portions 673, 674, for example, to provide an angled surface that is less susceptible to brute force attacks, such as hammer strikes on the shroud upper surfaces. For example, the upper surfaces 663a, 664a may extend at an angle 0 of between about 20 degrees to about 50 degrees, or about 30 degrees.

[0072] The shroud member 661 may be provided in a relatively hard, cut resistantmaterial (e g., tungsten carbide, boron carbide, ceramic composite (e.g., alumina, zirconia), titanium alloys, maraging steel) to impede cutting tool attacks to the shackle. Additionally or alternatively, the shroud member may be provided with one or more cut-resistant reinforcing inserts retained in cavities within the shroud member, for example, the reinforcing insert arrangements shown in the embodiments of FIGS. 2-17.

[0073] In accordance with other aspects of the present disclosure, other types of shackle shroud arrangements may additionally or alternatively be utilized. For example, a padlock may be provided with a shackle shroud enclosure (which may, but need not, be provided with one or more reinforcing inserts, as described above) that may be secured to the shackle without attachment to the lock body. FIG. 22 illustrates an exemplary embodiment of a shackle shroud760 having an enclosure 761 with surrounding side walls defining an interior cavity with an open bottom end, and including shackle leg receiving tube segments 766 welded to an interior surface of the enclosure. The shackle 750 may be installed into the shackle shroud enclosure761 and inserted through the tube segments 766 prior to assembly with the lock body 720, such that when the shackle is assembled with the lock body and moved to the locked position, the shackle shroud 760 is secured over the shackle. One or more cutouts 769 may be provided in the enclosure 761 to accommodate a secured structure (e.g., gate, hasp) over which the shackle 750 and enclosure are secured.

[0074] As another example, as shown in FIGS. 23A and 23B, a shackle shroud 860 (which may, but need not, be provided with one or more reinforcing inserts, as described above) may be secured to a padlock body 820 by a sliding arrangement that is secured in an extended, shackle blocking position (FIG. 23 A) when the padlock is in a locked condition, and is movable (e.g., against a spring biasing mechanism) to a retracted, shackle exposing position (FIG. 23B) when the padlock is in an unlocked condition, for example, to permit rotation of the open shackle 850.

[0075] In still other embodiments (not shown), a padlock may be provided with other (e.g., non-U-shaped) shackle configurations, including, for example, straight / linear shackles or circular shackles (e.g., as used in a discus type padlock). In such arrangements, a shackle shroud carrying one or more reinforcing inserts, in accordance with the present disclosure, may be assembled with or otherwise secured to the lock body for extension over a corresponding straight or curved portion of the shackle.

[0076] The inventive aspects have been described with reference to the exemplary embodiments. Modification and alterations will occur to others upon a reading and understanding of this specification. It is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.

Claims

We claim:

1. A shackle shroud for a padlock having a lock body defining first and second shackle bores extending to first and second shackle openings in a first end of the lock body and a shackle having first and second axially extending shackle legs receivable in the first and second shackle bores of the lock body, the shackle being moveable in an axial direction between a retracted position and an extended position, with at least one of the first and second shackle legs being withdrawn from the lock body in the extended position, the shackle shroud comprising: a shroud member having a base portion securable to the first end of the lock body and a first wall portion extending axially from the base portion to be positioned laterally outward of the first shackle leg when the shroud member is secured to the first end of the lock body; and at least a first reinforcing insert disposed in a first axially extending cavity in the first wall portion.

2. The shackle shroud of claim 1, wherein the first cavity extends an entire axial length of the first wall portion.

3. The shackle shroud of claim 1, wherein the first cavity forms a closed ended pocket in the first wall portion.

4. The shackle shroud of claim 1, wherein the first cavity forms an inwardly open channel in the first wall portion.

5. The shackle shroud of any of claims 1 - 4, wherein the first reinforcing insert comprises a plate.

6. The shackle shroud of any of claims 1 - 5, wherein the first reinforcing insert comprises at least one of tungsten carbide, boron carbide, alumina ceramic composite, zirconia ceramic composite, titanium alloys, maraging steel, graphene ceramic composite materials, and graphene metallic carbide composite materials.

7. The shackle shroud of any of claims 1 - 6, wherein the first reinforcing insert has a hardness greater than HRC 45.

8. The shackle shroud of any of claims 1 - 7, wherein the first cavity and the first reinforcing insert extend substantially parallel to the first shackle leg when the shroud member is secured to the first end of the lock body.

9. The shackle shroud of any of claims 1 - 8, wherein the first reinforcing insert extends an entire axial length from the lock body first end to a curved U-bend portion of the shackle when the shroud member is secured to the first end of the lock body.

10. The shackle shroud of any of claims 1 - 9, wherein the first cavity and the first reinforcing insert are tapered laterally inward from the shroud member base portion, such that when the shroud member is secured to the first end of the lock body, an upper portion of the first reinforcing insert is disposed at a first, smaller lateral distance from the first shackle leg and a lower portion of the first reinforcing insert is disposed at a second, larger distance from the first shackle leg.

11. The shackle shroud of claim 10, wherein the lower portion of the first reinforcing insert extends laterally outward of and beyond a junction between an exposed portion of the first shackle leg and the lock body first end when the shroud member is secured to the first end of the lock body.

12. The shackle shroud of any of claims 1 - 8, wherein the first reinforcing insert comprises an upper first reinforcing insert and the first cavity comprises an upper first cavity distal to the shroud member base portion, the shackle shroud further comprising a lower first reinforcing insert disposed in a lower first cavity proximal to the shroud member base portion.

13. The shackle shroud of claim 12, wherein when the shroud member is secured to the first end of the lock body, the upper first reinforcing insert is disposed at a first, smaller lateraldistance from the first shackle leg and the lower first reinforcing insert is disposed at a second, larger distance from the first shackle leg.

14. The shackle shroud of claim 13, wherein the lower first reinforcing insert extends laterally outward of and beyond a junction between an exposed portion of the first shackle leg and the lock body first end when the shroud member is secured to the first end of the lock body.

15. The shackle shroud of any of claims 1 - 14, wherein the shackle shroud further comprises a second wall portion extending axially from the base portion and laterally outward of the second shackle leg when the shroud member is secured to the first end of the lock body.

16. The shackle shroud of claim 15, wherein the shackle shroud further comprises at least a second reinforcing insert disposed in a second axially extending cavity in the second wall portion.

17. The shackle shroud of claim 16, wherein the second cavity extends an entire axial length of the second wall portion.

18. The shackle shroud of claim 16, wherein the second cavity forms a closed ended pocket in the second wall portion.

19. The shackle shroud of claim 16, wherein the second cavity forms an inwardly open channel in the second wall portion.

20. The shackle shroud of any of claims 16 - 19, wherein the second reinforcing insert comprises a plate.

21. The shackle shroud of any of claims 16 - 20, wherein the second reinforcing insert comprises at least one of tungsten carbide, boron carbide, alumina ceramic composite, zirconia ceramic composite, titanium alloys, maraging steel, graphene ceramic composite materials, and graphene metallic carbide composite materials.

22. The shackle shroud of any of claims 16 - 21, wherein the second reinforcing insert has a hardness greater than HRC 45.

23. The shackle shroud of any of claims 16 - 22, wherein the second cavity and the second reinforcing insert extend substantially parallel to the second shackle leg when the shroud member is secured to the first end of the lock body.

24. The shackle shroud of any of claims 16 - 23, wherein the second reinforcing insert extends an entire axial length from the lock body first end to a curved U-bend portion of the shackle when the shroud member is secured to the first end of the lock body.

25. The shackle shroud of any of claims 16 - 24, wherein the second cavity and the second reinforcing insert are tapered laterally inward from the shroud member base portion, such that when the shroud member is secured to the first end of the lock body, an upper portion of the second reinforcing insert is disposed at a first, smaller lateral distance from the second shackle leg and a lower portion of the second reinforcing insert is disposed at a second, larger distance from the second shackle leg.

26. The shackle shroud of claim 25, wherein the lower portion of the second reinforcing insert extends laterally outward of and beyond a junction between an exposed portion of the second shackle leg and the lock body first end.

27. The shackle shroud of any of claims 16 - 23, wherein the second reinforcing insert comprises an upper second reinforcing insert and the second cavity comprises an upper second cavity distal to the shroud member base portion, the shackle shroud further comprising a lower second reinforcing insert disposed in a lower second cavity proximal to the shroud member base portion.

28. The shackle shroud of claim 27, wherein when the shroud member is secured to the first end of the lock body, the upper second reinforcing insert is disposed at a first, smaller lateraldistance from the second shackle leg and the lower second reinforcing insert is disposed at a second, larger distance from the second shackle leg.

29. The shackle shroud of claim 28, wherein the lower second reinforcing insert extends laterally outward of and beyond a junction between an exposed portion of the second shackle leg and the lock body first end when the shroud member is secured to the first end of the lock body.

30. The shackle shroud of any of claims 1 - 29, wherein the shroud member comprises at least one of tungsten carbide, boron carbide, alumina ceramic composite, zirconia ceramic composite, titanium alloys, and maraging steel.

31. The shackle shroud of any of claims 1 - 30, wherein the shroud member has a hardness between HRC 45 - 65.

32. The shackle shroud of any of claims 1 - 31, wherein the base portion of the shroud member includes an outer wall defining a downward facing recess sized and shaped to receive the first end of the lock body.

33. The shackle shroud of claim 32, further comprising one or more deformable inner nubs disposed on an inner perimeter of the outer wall to provide for press fit retention of the shackle shroud on the first end of the lock body.

34. The shackle shroud of any of claims 1 - 33, wherein the shroud member further includes a second wall portion extending axially from the base portion, wherein the first and second wall portions include corresponding first and second rear wall portions spaced apart by a first lateral dimension sized to receive the first and second shackle legs therebetween when the shroud member is secured to the first end of the lock body, and corresponding first and second front wall portions spaced apart by a second lateral dimension smaller than the first lateral dimension to limit access to the shackle by a cutting tool.

35. The shackle shroud of claim 34, wherein the first and second wall portions further comprise corresponding first and second medial wall portions disposed between the corresponding first and second front wall portions and the first and second rear wall portions and spaced apart by a third lateral dimension smaller than the first lateral dimension and larger than the second lateral dimension.

36. The shackle shroud of any of claims 32 - 25, wherein the first and second wall portions further comprise an upper portion extending at an upward angle from the first and second rear wall portions to the first and second front wall portions.

37. The shackle shroud of claim 36, wherein the upward angle is between about 20 degrees and about 50 degrees, or about 30 degrees.

38. A padlock assembly comprising: a padlock comprising: a lock body defining first and second shackle bores extending to first and second shackle openings in a first end of the lock body; and a shackle having first and second axially extending shackle legs receivable in the first and second shackle bores of the lock body, the shackle being moveable in an axial direction between a retracted position and an extended position, with at least one of the first and second shackle legs being withdrawn from the lock body in the extended position; and the shackle shroud of any of claims 1 - 37, wherein the base portion of the shroud member is secured to the first end of the lock body.

39. A locking system, comprising: a padlock including a lock body and a shackle having first and second shackle legs extending axially from a first end of the lock body and joined by a bight portion of the shackle; a hasp unit including a mounting portion and a loop portion extending from the mounting portion and defining an aperture sized to receive the bight portion of the shackle and having a thickness sized to be received between the first and second shackle legs; anda shackle shroud including a shroud member having a base portion securable to the first end of the lock body and first and second wall portions extending axially from the base portion, the first and second wall portions having corresponding first and second rear wall portions spaced apart by a first lateral dimension sized to receive the first and second shackle legs therebetween when the shroud member is secured to the first end of the lock body, and corresponding first and second front wall portions spaced apart by a second lateral dimension smaller than the first lateral dimension and sized to be substantially spanned by a forward portion of the loop portion when the shroud member is secured to the first end of the lock body and the padlock shackle is installed through the loop portion, thereby blocking access to the shackle bight portion by a cutting tool.

40. The locking system of claim 39, wherein the first and second wall portions further comprise corresponding first and second medial wall portions disposed between the corresponding first and second front wall portions and the first and second rear wall portions and spaced apart by a third lateral dimension smaller than the first lateral dimension and larger than the second lateral dimension to receive a forward portion of the loop portion therebetween when the shroud member is secured to the first end of the lock body and the padlock shackle is installed through the loop portion.

41. The locking system of any of claims 39 - 40, wherein the first and second wall portions further comprise an upper portion shaped to prevent forward pivoting movement of the lock body about the bight portion beyond a pivot angle of about 120 degrees, or beyond a pivot angle of about 90 degrees, when the shroud member is secured to the first end of the lock body and the padlock shackle is installed through the loop portion.

42. The locking system of any of claims 39-41, wherein an upper surface of the first and second wall portions extends axially outward from the first and second rear wall portions to the first and second front wall portions.

43. The locking system of claim 42, wherein the upper surface of the first and second wall portions extends axially outward at an angle between about 20 degrees and about 50 degrees,or about 30 degrees.

44. The locking system of any of claims 39 - 43, wherein at least the first and second front wall portions extend beyond the bight portion of the shackle when the shroud member is secured to the first end of the lock body.

44. The locking system of any of claims 39 - 43, wherein the shackle shroud comprises the shackle shroud of any of claims 1 - 37.

45. A locking system, comprising: a padlock including a lock body and a shackle having first and second shackle legs extending axially from a first end of the lock body and joined by a bight portion of the shackle; a hasp unit including a mounting portion and a loop portion extending from the mounting portion and defining an aperture sized to receive the bight portion of the shackle and having a thickness sized to be received between the first and second shackle legs; and a shackle shroud including a shroud member having a base portion securable to the first end of the lock body and first and second wall portions extending axially from the base portion to receive the first and second shackle legs therebetween when the shroud member is secured to the first end of the lock body; wherein the first and second wall portions further comprise an upper portion shaped to prevent forward pivoting movement of the lock body about the bight portion beyond a pivot angle of about 120 degrees, or beyond a pivot angle of about 90 degrees, when the shroud member is secured to the first end of the lock body and the padlock shackle is installed through the loop portion.

46. The locking system of claim 45, wherein an upper surface of the first and second wall portions extends axially outward from the first and second rear wall portions to the first and second front wall portions.

47. The locking system of claim 46, wherein the upper surface of the first and second wall portions extends axially outward at an angle between about 20 degrees and about 50 degrees,or about 30 degrees.

48. The locking system of any of claims 45 - 47, wherein at least the first and second front wall portions extend beyond the bight portion of the shackle when the shroud member is secured to the first end of the lock body.

49. The locking system of any of claims 45 - 48, wherein the shackle shroud comprises the shackle shroud of any of claims 1 - 37.

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