Integrally Molded Padlock Insertion Part Assembly
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Solution Overview
Problem
The assembly of ring hoop padlocks is complex and expensive due to the need for multiple assembly steps and components, particularly the insertion parts which are often welded or screwed together.
Innovation Solution
A ring hoop padlock design featuring an integrally single-piece insertion part that is manufactured by casting or injection molding, allowing for simplified assembly and providing a defined guidance for the ring hoop, with guide sections for smooth movement and enhanced security.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If insertion parts are assembled from multiple components (front plate and rear plate connected via riveted pins), then the structural strength is improved, but the assembly complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the front plate and rear plate into a single integrally-bonded insertion part. This eliminates the need for riveted pins connecting separate plates, thereby reducing assembly complexity while maintaining structural integrity through the monolithic design.
Solution Approach 2:
The insertion part is designed as a single integrated component that can be manufactured separately and then inserted as one unit into the housing. This segmentation of the manufacturing process from assembly allows complex structural requirements to be met without increasing overall assembly complexity.
2Strength
If insertion parts are welded to the housing for fixed connection, then the connection strength is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The insertion part and housing are designed to form a fixed connection through precise geometric fitting and friction engagement rather than welding. This eliminates thermal processes and additional manufacturing steps while maintaining strong mechanical connection.
Solution Approach 2:
The insertion part is designed with self-aligning features and self-retaining geometry that enable it to be firmly secured in the housing through simple insertion. The design inherently provides its own fixation mechanism through friction and geometric constraints, eliminating the need for external welding operations.
3Reliability
If multiple assembly steps are used for complex insertion part assembly, then the connection reliability is improved, but the assembly time and productivity decrease
Solution Approach 1:
The insertion part is pre-manufactured as a complete, integrally-bonded component with all necessary features already in place. This preliminary preparation of the insertion part as a ready-to-install unit eliminates the need for on-site assembly operations, reducing assembly time while ensuring reliable connections through factory-controlled manufacturing.
4Ease of manufacture
If an integrally single-piece insertion part is used, then the assembly simplicity and manufacturing speed are improved, but the structural complexity increases
Solution Approach 1:
The insertion part is manufactured using casting or injection molding processes that enable complex three-dimensional geometries to be created as single-piece components. These manufacturing parameters allow the structural complexity to be achieved during manufacturing rather than through assembly, simplifying the final assembly process.
Data Source
AI summary
A ring hoop padlock comprises a ring hoop rotatable about an axis of rotation; a lock cylinder that has a cylinder housing and a rotatable cylinder core; an entrainer coupled to the cylinder core for driving the ring hoop; a housing that has a front housing part and a rear housing part; and an insertion part in which the lock cylinder is held, with the insertion part being integrally formed in one piece.