Flexible-Shackle Padlock Guide for Precise Locking Alignment
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Solution Overview
Problem
Flexible shackles in U-locks can rotate relative to each other during loop formation, necessitating complex insertion positions and compromising security due to material removal for circumferential grooves or requiring precise rotational alignment, leading to instability and inconvenience.
Innovation Solution
Incorporation of a guide device on the shackle to define a specific insertion rotation position, ensuring the first shackle end is aligned correctly for locking, preventing rotation relative to the insertion axis, and using shape-sensing elements to align the shackle ends for secure and easy operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a circumferential groove is provided on the first shackle end to allow locking at any rotational position, then the ease of operation is improved, but the strength and stability of the shackle deteriorate due to material removal
Solution Approach 1:
Instead of removing material circumferentially, the invention creates a localized recess at a specific position on the shackle end. This recess is designed to engage with a corresponding feature on the lock body, providing a positive locking position without compromising the overall structural integrity of the shackle. The localized approach maintains strength while enabling reliable locking.
Solution Approach 2:
The invention introduces an intermediary engagement feature (the recess on the shackle end that fits into a feature on the lock body) to mediate between the shackle and lock body. This intermediary mechanism provides precise rotational positioning and secure locking without requiring material removal that would weaken the shackle structure.
2Strength
If only a local recess is provided at the first end of the shackle for bolt engagement, then the strength and stability are maintained, but the ease of operation deteriorates as the shackle must be inserted at the correct rotational position
Solution Approach 1:
The recess is positioned asymmetrically on the shackle end, creating a unique engagement orientation. This asymmetric design, combined with the corresponding asymmetric feature on the lock body, ensures that the shackle can only be inserted into the lock body in the correct rotational position, providing both security and reliable locking.
Solution Approach 2:
The recess and corresponding lock body feature are designed to guide the shackle into the correct rotational position during insertion. The geometry of these features performs the preliminary action of aligning the shackle properly before the locking engagement occurs, making the insertion process straightforward despite the requirement for precise orientation.
3Adaptability or versatility
If the first shackle end is made rotatable about the insertion axis to accommodate loop formation, then the adaptability is improved, but the manufacturing precision and alignment accuracy deteriorate
Solution Approach 1:
The shackle end is designed with rotational freedom during the loop formation process, allowing dynamic adjustment to accommodate various configurations. However, the recess feature provides a fixed reference that locks this dynamic positioning, ensuring that once the shackle is inserted, it achieves precise alignment and maintains manufacturing accuracy.
Solution Approach 2:
The function of the shackle end is segmented into two phases: during insertion and loop formation, the shackle end can rotate to accommodate different positions; after insertion, the recess engages with the lock body feature to fix the rotational position and ensure precise alignment. This segmentation allows both adaptability and precision to be achieved at different stages.
Data Source
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AI summary
A padlock comprises a lock body, a flexible shackle, and a locking mechanism. A first shackle end can be inserted into the lock body along an insertion axis and can be selectively locked to the lock body or released from it by the locking mechanism. A second shackle end can be attached to the lock body or is permanently fixed to it. When the second shackle end is attached to the lock body, the first shackle end, when detached from the lock body, can rotate about the insertion axis. Furthermore, the flexible shackle includes a guide for defining an insertion/rotational position of the first shackle end, in which the first shackle end can be inserted into the lock body and/or locked.