Dual Locking Padlock with Key Override and Combination Reset
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Solution Overview
Problem
Current padlocks do not meet the new security regulations that require customs officers to physically break locks for inspection, as they lack a dual locking mechanism that allows secure access and re-locking without damaging the lock.
Innovation Solution
A padlock with a dual locking mechanism that can be opened by either a combination code or a key, featuring a spindle with clutches and dials for code-based operation and an overriding mechanism for key-based operation, ensuring secure access and re-locking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single locking mechanism is used, then the device complexity is reduced, but the reliability under new security regulations deteriorates because customs officers must break the lock for inspection
Solution Approach 1:
The locking mechanism is divided into two independent subsystems: a first locking mechanism (combination lock with spindle, clutches, and dials) and a second locking mechanism (key-operated override mechanism). Each subsystem can independently lock and unlock the shackle, allowing customs officers to use the key mechanism for inspection without damaging the combination mechanism, thus resolving the contradiction between reliability under security regulations and device complexity.
2Ease of operation
If a combination locking mechanism is used, then the ease of operation is improved for users, but the reliability deteriorates under security regulations requiring physical breaking of locks
Solution Approach 1:
The key-operated second locking mechanism serves as an intermediary solution that satisfies security regulations. Customs officers can use this mechanism to unlock the shackle for inspection without needing to break the combination lock, while regular users continue to benefit from the ease of operation of the combination mechanism. This intermediary mechanism resolves the contradiction between user convenience and regulatory compliance.
3Reliability
If dual locking mechanisms are implemented, then the reliability under security regulations is improved, but the device complexity increases
Solution Approach 1:
The patent merges two locking mechanisms (combination lock and key-operated override) into a single integrated padlock body sharing common components like the shackle, lock housing, and spring mechanism. This merging approach achieves the reliability required by security regulations while minimizing device complexity by avoiding complete duplication of components, thus resolving the contradiction between reliability and complexity.
4Ease of operation
If the shackle can be partially released, then the ease of operation for inspection is improved, but the reliability of locked mode deteriorates
Solution Approach 1:
The shackle is designed with dynamic positioning capability, allowing it to be partially released from the lock housing between the first shackle position (fully locked) and the second shackle position (partially released for inspection). The spring mechanism dynamically adjusts to maintain secure locking when in the first position while enabling controlled partial release for customs inspection, resolving the contradiction between operational ease for inspection and locked mode reliability.
Data Source
AI summary
A dual locking padlock having a code locking mechanism and an overriding mechanism is disclosed. The housing has a top body, a stack of dials and clutches mounted on a bottom body, and a spindle engaging with the clutches. The spindle has a channel to store the heel of a shackle. An upward movement of the spindle allows the shackle to be pulled upward to unlock the padlock. Each dial has a plurality of teeth with slope-like surfaces to engage with the wave slots of a clutch. Clutches are rotatable relative to the spindle only when the lock is in the locked mode along with the dials. In the opened mode, a dial can be turned relative to a clutch by disengaging the teeth from wave-slots. The spindle is allowed to move upward either when a correct combination code is used or when a key activates the overriding mechanism.