AU785481B2 - Padlocks - Google Patents

Description

P/00/011 Regulation 3.2

AUSTRALIA

Patents Act 1990

ORIGINAL

COMPLETE SPECIFICATION STANDARD PATENT #oooo* o oO* *o oo Invention title: Padlocks The following statement is a full description of this invention, including the best method of performing it known to us: dxbm M0110948154v1 154008 STANDARD PATENT APPLICATION Title Padlocks Applicant: Yarra Ridge Pty Ltd Inventor J Russell Watts Address: 8 Ross Street, South Melbourne, Australia 3205 Address for Correspondence: PO Box 275 Albert Park, Victoria 3206 Email: russell.watts@ausloc.com The following statement is a full description of this invention, including the best method of performing it known to me:- FROM A~USTRARL LCK PHONE NO. 61396865755 Alug. 15 2007 0~:09M PG Title Padlocks Summary of the Invention According to an invention, there is a padlock, including a shackle having a first leg with a first locking recess and a longer leg having an opposed second locking recess, the opposed second locking recess being connected by a longitudinally elongated recess to a peripheral recess disposed towards the end of the longer leg, and a casing having a first and a longer casing recess extending into the casing from a first end surface to accept the first and longer shackle leg respectively, a central recess extending into the casing from an opposed second end surface, an offset recess extending into the casing from the opposed second end surface and connected to the central recess, the first casing, longer casing and central recesses being intersected by a transverse recess extending into the casing from a first side of the casing, a cylinder having a key operable barrel characterized by an undisplaced position enabling key removal, two opposed balls supported within the transverse recess; a first ball to protrude into the first casing recess and first locking recess and a second ball to protrude into the longer casing recess and second locking recess, a cam including a first cam portion to control the balls and a cam drive portion that includes at least one drive recess, COMS ID No: ARCS-157099 Received by IP Australia: Time 14:28 Date 2007-08-15 FROM AUSTRAL LOCK PHONE NO. 61396865755 Aug. 15 2007 04:09PM P7 2 the cam operable by the barrel through coupling means that occupies a hole within the at least one drive recess to provide a Type 2 padlock, the cam operable by the barrel through coupling means that occupies the at least one drive recess without projecting into the hole to provide a Type 1 padlock, said Type 1 padlock being characterized by an open configuration where the first leg is free of the casing, the longer leg is supported in the casing and the key is removable, said Type 2 padlock being characterized by an open configuration where the first leg is free of the casing, the long leg is supported in the casing and the key and barrel cannot be rotated to the undisplaced position to enable key removal.

In forms of the invention, the first cam portion comprises a substantially cylindrical portion having a peripheral curved side surface defined in part by a longitudinal axis coaxial with an axis of rotation of the cam which is parallel to and between the longitudinal axii of the first casing and longer casing recesses, 15 the cam in a locking configuration presenting the curved side surface to each ball *to retain each ball in its corresponding locking recess, the cam in the unlocking configuration presenting a first unlocking side recess to the first ball and a second unlocking side recess to the second ball to enable the first ball to be removed from the first locking recess and to enable the second ball to be removed 20 from the second locking recess to be retained partly within the longitudinally elongated recess or the peripheral recess.

In forms of the invention, the angular disposition of the first cam portion in the locking and unlocked configurations is determined by a stop that includes an outwardly projecting stop shoulder that protrudes into the offset recess, the stop being displaceable 25 between a first operative configuration where the stop shoulder abuts the wall of the offset recess and a second operative configuration where the stop shoulder abuts the opposite wall of the offset casing, the padlock being characterized by: a locked configuration corresponding to the stop portion being in the first operative configuration, the first and longer legs being supported in the casing and restrained from displacing relative to the casing, the cam being in a locking configuration retaining the first ball partly within the first locking recess and the second ball being partly within the second locking recess, the cam and stop being rotatable in an unlocking direction by the cylinder to displace the cam to an unlocking configuration, and COMS ID No: ARCS-157099 Received by IP Australia: Time 14:28 Date 2007-08-15 FROM AUSTRAL LOCK FROM RUS~~l~L LOCK HONE NO. :61396865755Pu.12074!1' B Aug. 15 2007 04:10PM Pe 3 an unlocked configuration corresponding to the stop portion being in the second operative configuration, the first leg being tree of the casing, the longer leg being supported in the casing, and the cam being in an unlocking configuration retaining the second ball partly within the longitudinally elongated recess or partly within the peripheral recess.

In forms of the invention, the coupling means is removable to enable the cam to be rotated in the unlocking direction from the unlocking configuration while the stop portion remains in the second operative configuration, said cam being displaceable to a removal configuration characterized by the cam presenting a third side recess, deeper than the second recess, to the second ball to enable the second ball to be removed from all the recesses of the longer leg, to enable long leg to be removed from the casing, In forms of the invention, the at least one drive recess has a drive shoulder at one end and a stop shoulder at the other end, and wherein the stop has an Inwardly protruding finger that protrudes into the drive recess, wherein the finger abuts the drive shoulder when the cam is in the locking and unlocking configurations, and in the removal :configuration the cam is angularly displaced in an unlocking direction from the unlocked disposition to a position where the finger abuts a respective stop shoulder.

In forms of the invention, the padlock is configured as a Type 1 padlock, wherein C the coupling means includes at least one drive pin that occupies the at least one drive recess said drive pin being displaceable about the axis of rotation of the barrel to displace the cam to the unlocking configuration, the barrel and key being displaceable subsequently to the undisplaced position while the drive pin correspondingly displaces freely within the drive recess.

In forms of the invention, the cam includes a pair of opposed drive recesses and a >2.25 pair of opposed drive pins, a first of said drive recesses occupied by a first of said drive pins and a second of said drive recesses occupied by a second of said drive pins.

**In forms of the invention, the padlock is configured as a Type 2 padlock, wherein the coupling means includes at least one dnive pin that occupies the additional hole in the at least one drive recess, said drive pin being displaceable about an axis of rotation of the barrel to displace the cam to the unlocking configuration whereupon the cam becomes restrained and the barrel and key become restrained from displacing to the undisplaced position by the drive pin being within additonal hole of the restrained cam.

In forms of the invention, the cam includes a pair of opposed drive recesses and the coupling means comprises a pair of opposed drive pins and an additional hole of a COMS ID No: ARC-S-157099 Received by iP Australia: Time 14:28 Date 2007-M815 FROM R USTRAL LOCK PHONE NO. 61396865755 Aug. 15 200? 04: i0PIM P9 4 first of said drive recesses is occupied by a first of said drive pins and an additional hole of the second of said dnive recesses is occupied by a second of said drive pins.

In forms of the invention, each drive pin is supported in a longitudinally elongated barrel drive recesses.

In forms of the invention, each drive pin has passage through while being supported in a support disc to comprise a sub-assembly comprising a coupler, each said drive pin being configured to protrude more from one side of the support disc than the other and additionally being configured so that when assembled into the padlock casing with the longer end towards the cam, each said drive pin protrudes into an additional hole in the cam whereby to provide a Type 2 padlock, and when assembled into the padlock casing with the shorter ends towards the cam, each said drive pin protrudes into a drive recess but not into a hole whereby to provide a Type 1 padlock.

In forms of the invention, the longitudinal axis of each barrel drive recess when the barrel is undisplaced, is substantially coaxial with the longitudinal axis of a corresponding additional hole.

According to an invention, there is a padlock including a shackle having a first leg with a first locking recess and a longer leg having an opposed second locking recess, said :opposed second locking recess being connected by a longitudinally elongated recess to a peripheral recess disposed towards the end of the longer leg, and a casing having a first casing recess and a longer casing recess extending into the casing from a first end surface to accept the first and longer shackle leg respectively, a central recess extending into the casing from an opposed second end surface, an offset recess extending into the casing from the opposed second end surface and intersecting the central recess, *25 said first casing, longer casing and central recesses being intersected by a transverse recess extending into the casing from a first side of the casing, a cylinder having a key operable barrel characterized by an undisplaced position enabling key removal, two opposed balls supported within the transverse recess, a first ball to protrude into the first casing recess and first locking recess and a second ball to protrude into the longer casing recess and second locking recess, a cam including a first cam portion to control the balls and a cam drive. portion that includes at least one drive recess, the cam being operable by the barrel through an Interspaced coupling member that meshes with the cam while meshing with the barrel to provide a Type 1 padlock, COMS 0 No: ARcS-157099 Received by IP Austraiia: Time 14:28 Date 2007-08-15 FROM AUSTRAL LOCK FONE NO. 61396865755 Aug. 15 2007 0:1PM the cam operable by the barrel through an inverted coupling member that meshes differently with the cam while meshing with the barrel to provide a Type 2 padlock.

said Type 1 padlock being characterized by an open configuration where the first leg is free of the casing, the longer leg is supported in the casing and the key is removable, said Type 2 padlock being characterized by an open configuration where the short leg is free of the body, the long leg is supported in the body casing and the key and barrel cannot be rotated to the undisplaced position to enable key removal.

In forms of the invention, there is a torsion spring supported relative to the cam, said torsion spring having one end attached to the cam and another end within the offset recess to bias the cam towards the locking configuration.

In forms of the invention, there is a compression spring within the longer recess to bias the shackle from the body.

In forms of the invention, the cylinder comprises an interchangeable core retained 15 in the casing by a sideways protruding shoulder that is displaceable into the core by S:application of a control key whereby to enable the cylinder to be removed to enable the coupling means to be removed.

In forms of the invention, the cylinder is retained in the casing by a screw that has passage through an aperture in the casing, said screw being removable to enable the 20 cylinder and coupling means to removed.

In forms of the invention, a cross-section of the longitudinally elongated recess is defined in part by a radius substantially the same as the radii of the second ball.

In forms of the invention, the second locking recess is substantially spherical in form and defined in part by a radius substantially the same as the radii of the second ball 25 whereby to provide a stronger shackle.

In forms of the invention, the first locking recess is substantially spherical in form S. and defined in part by a radius substantially the same as the radii of the first ball whereby to provide a stronger shackle.

According to an invention, there is a padlock substantially as described herein with reference to and as illustrated in the accompanying figures.

COMS ID No: ARCS-157099 Received by IP Australia: Time 14:28 Date 2007-08-15 DESCRIPTION OF THE FIRST PREFERRED EMBODIMENT Description of the Drawings Embodiments of the present invention will now be described by way of example only with reference to the accompanying drawings in which: Fig 1 is a schematic side view of a padlock with the shackle removed, Fig 2 is a schematic partial sectional view AA of the padlock of Fig 1, Fig 3 is a schematic partial sectional view BB of the padlock of Fig 1 Fig 4 is a partly cut away isometric view of the padlock of Fig 1 Fig 5 is an exploded, isometric view looking from above, of the cam and adjacent components, Fig 6 is an exploded, isometric view looking from below, of the cam and adjacent components, Fig 7 is an isometric view looking from below, of the cam and drive pins when configured for a Type 1 padlock, Fig 8 is an isometric view looking from below, of the cam and drive pins when configured for a Type 2 padlock, Fig 9 is a schematic side view of an unlocked padlock having an open shackle, Fig 10 is a schematic partial sectional view AA of the padlock of Fig 9, S•Fig 11 is a schematic partial sectional view BB of the padlock of Fig 9 I 20 Fig 12 is a partlycut away isometric view of the padlock of Fig 9 Fig 13 is a schematic side view of a locked padlock having a closed and latched shackle, Fig 14 is a schematic partial sectional view AA of the padlock of Fig 13, Fig 15 is a schematic partial sectional view BB of the padlock of Fig 13 Fig 16 is a partly cut away isometric view of the padlock of Fig 13 Fig 17 are isometric views of the removed shackle showing the first and second locking recess and the longitudinal and peripheral recesses Fig 18 is a sectional view defined by a plane which intersects the longitudinal axis of the shackle Fig 19 is a schematic side view of a padlock employing a removeable cylinder Fig 20 is a partly cut-away exploded, isometric view looking from above, of the padlock of Fig 19 Fig 21 is a schematic side view of a padlock employing an interchangeable core Fig 22 is a partly cut-away exploded, isometric view looking from above, of the padlock of Fig 21 is a schematic side view of a padlock employing an interchangeable core showing the undercut cylinder-retaining recess, Fig 23 is a schematic side view of a cutting tool and shackle blank Fig 24 is a schematic, isometric view of the shackle blank being formed Fig 25 is an exploded, isometric view of alternative drive pins and an alternative pin-holder.

A "closed" padlock, unless the context requires otherwise, is characterized by each leg of the shackle being within its respective casing recess and having its respective locking recess disposed to receive a locking ball; An open padlock, unless the context requires otherwise, is characterized by the first leg of the shackle being displaced from the first casing recess and the cam being in a "unlocking configuration" A "locked" padlock, unless the context requires otherwise, is characterized by being closed and where each locking recess is occupied by a locking ball that is restrained against departure by the cam. A locked padlock, unless the context requires otherwise, is characterized by the cam being in a "locking configuration" characterized by the balls abutting a side surface of the cam, unable to move inwardly to release the shackle legs.

S 20 A scallop is a surface that is defined in one direction by a curved flat surface The invention provides improvements in padlocks including improvements in padlock shackles, cams and cylinders, and means for manufacturing padlocks including means for manufacturing shackles, cams and cylinders. It is envisaged that elements of the invention, including the improved cam, shackle and cylinder be transported in other 25 locking devices.

Improvements in padlocks reference two types of padlocks; a Type 1 padlock that may be opened while having the key removed from the cylinder, and a Type 2 padlock where the key cannot be removed unless the shackle is closed.

In preferred embodiments, the padlock can be converted between a Type 1 30 padlock and a Type 2 padlock by simply re-configuring components while in other preferred embodiments, the padlock can be converted between a Type 1 padlock and a Type 2 padlock by simply re-orientating a removeable sub-assembly, without the need for special tools and without additional parts.

In preferred embodiments, the padlock employs a removeable cylinder retained by a removeable screw, while in other improved padlocks, the padlock employs, what is 8 commonly called, an interchangeable core which is removeable by the application of a control key.

In preferred embodiments the padlock employs a shackle of well known design comprising a pair of substantially parallel, preferably cylindrical, legs; one first leg and one longer leg, connected by a connecting portion preferably comprising part of a torus.

Towards the held end of the first leg and facing the longer leg is a first locking recess and directly opposite in the longer leg and facing the first leg is a second locking recess.

Towards the end of the longer leg is a peripheral recess that is connected to the second locking recess by a longitudinally disposed flat. The locking recesses and flat comprise scallops in the side of the shackle body that may be manufactured by broaching the shackle body from the side after the shackle body has been formed into the horse-shoe shape.

In preferred embodiments, the padlock employs a shackle 1 of well known design, as shown in Fig 4 and 17, comprising a pair of substantially parallel, substantially cylindrical legs; one first leg 2 (also referred to as "a short leg") and one longer leg 3, connected by a connecting portion 4 preferably comprising part of a torus. Towards the free end of the first leg 2 and facing the longer leg 3 is a first locking recess 6 and directly opposite in the longer leg 3 and facing the first leg 2 is a second locking recess 7.

*Towards the free end of the longer leg is a peripheral recess 8 which is connected to the g 20 second locking recess by a longitudinally disposed flat 9 if the shackle is of conventional design or a longitudinally disposed channel 10 if the shackle employs the improved design described herein. The locking recesses and flat of well know designs comprise scallops in fee, the side of the shackle body manufactured by broaching the shackle body from the side after the shackle body has been formed into the generally horse-shoe shape.

25 In other preferred embodiments, the padlock employs a shackle 1 of improved l design, as shown in Fig 4, 17 and 18, comprising a pair of substantially parallel substantially cylindrical legs, a first leg 2 and one longer leg 3, connected together by a connecting portion 4 preferably comprising part of a torus. Towards the free end of the S° first 2 and facing the longer leg is a first locking recess 6 and directly opposite in the 30 longer leg and facing the short leg 2 is a second locking recess 7. Towards the free end of S"the longer leg is a peripheral recess 8 that is connected to the second locking recess by a longitudinally longitudinally elongated channel Fig 18, shows the preferred shackle, defined in part by by a central plane that passes through the longitudinal axis of the legs of the shackle and the sectional A-A view Fig 18, is defined by this central plane. In relation to this view, the peripheral recess at the deepest point 11 defined by dimension 11A, and channel at the deepest point 12 defined by dimension 12A, are substantially the same; i.e. the depths from inside edge of the sectioned view of the longer shackle leg are substantially the same and a lesser depth than the depth of the second locking recess at the deepest point 14 defined by dimension 14A described in more detail below In preferred embodiments, as shown in Fig 1 to 4, the padlock includes a body including a casing 16 having a first casing recess 17 (also referred to as "a short casing bore") extending into the casing from a first end surface 19 to receive the first shackle leg 2 and a longer second casing recess 18 extending into the casing from the first end surface 19 to receive the longer shackle leg 3, and a transverse recess 20 (also referred to as a cross recess) in the vicinity of the first end surface 19 commencing at a first side surface 21 of the body and intersecting the first and second casing recesses and in the region of the first casing recess having a constriction 22 of reduced cross-section so the first locking ball 23 described below, cannot pass from transverse recess 20 into the first casing recess 17 Preferably the axis of the transverse 20 orthogonally intersects the axii of the first and second casing recesses 17 and 18 which are preferably parallel and substantially cylindrical the recesses preferably being formed by a rotating cutter tool that is advanced into the padlock casing from the first end surface 19.

The padlock is configurable such that in a locked configuration the first leg 2 including the first locking recess 6 is within the first casing recess 17 and the longer leg 3 including the second locking recess 7 is within the longer casing recess 18 and Soadditionally, the locking recesses 6 and 7 are substantially aligned with the transverse recess 20. Preferably, in this configuration, the deepest point 14 of the second locking 25 recess 14 (that may comprise the short longitudinal channel- described below), is at least in part, substantially co-axial with the axis of the transverse recess.

In the locked configuration, Fig 13 to 16, the first ball 23 locates partly within the first locking recess 6 and partly in the transverse recess 20 and a second locking ball 24 lies partly in the second locking recess 7 and partly within the transverse recess Between the balls is a displaceable, (preferably angularly displaceable), cam 25 of varying cross-section. The locked configuration of the padlock as shown, is characterized by the °°ooo cam being in a locking configuration characterized by the balls abutting a side surface 26 of the cam, this engagement preventing the balls from moving inwardly to release the shackle legs.

When the cam is in the unlocking configuration as shown in Fig 9 to 12, the first ball 23 is partly within a first unlocking recess 27 of the cam able to completely withdrawn from the first locking recess 6 in the first leg to thereby release the first leg. Opposite this first unlockinging recess 27 is a second, less deep similar second unlocking recess 28.

When the cam is in the unlocked configuration and the first leg is released the second ball is partly within the second unlockinging recess 28 and partly within the second locking recess 7 or partly within the peripheral recess or partly within the longitudial recess (thay may comprise a flat 9 or channel 10 depending on the shackle configuration). During unlatching the second ball is retained in this flat or channel as the shackle is moved longitudinally in relation to the casing to enable the first leg to withdraw from the first casing recess to a configuration where the second ball 24 is in the second cam unlocking recess 28 and partly within the peripheral recess enabling the shackle to be rotated in relation to the body while being retained in the body.

The casing is defined by a first end surface 19 referred to above, an opposed second end surface 29, a first side surface 21 referred to above, an opposed second side surface 30, a front surface 31 and a back surface 32.

Coaxial with the axis of rotation of the cam is a central recess 33 that extends into the casing from the second end surface 29 to provide a recess for the cam while accommodating a cylinder barrel; this central recess being intersected by the transverse recess.

In a preferred embodiment employing a removable cylinder there is adjacent to the central recess 33, an offset recess 34 of lesser depth, having a longitudinal axis parallel to that of the central recess and displaced sideways from that of the central recess such that i 25 this recess is intercepted by the axis of the short recess 7. The offset recess has a depth not so great as to intersect recess 17 by which it is separated by a bridge portion 35. The central recess and offset recess preferably each comprise cylindrical recesses having axii parallel to those of the recesses 17 and 18 to together form a chamber of a generally figure 8 cross-section to accommodate a cylinder of similar cross-section In some preferred embodiments, the central recess comprises a first substantially cylindrical portion joined coaxially to a substantially cylindrical second portion of smaller diameter, said latter portion supporting the cam while being intersected by the transverse recess.

"In some forms the offset recess comprises a parallel sided oval so that together the oval and offset recess form a substantially pear shaped recess to accommodate a cylinder of common European profile. And in some forms the 11 combined recesses are of Fig 8 cross-section configured to accept an interchangeable core in which case, the offset recess need not be intercepted by the axis of the first casing recess 17.

The offset recess extending towards the first casing recess provides the bridge portion 35 between these recesses 34 and 17. In embodiments not employing an interchangeable core, this bridge portion includes an aperture 36 which extends from the recess 17 to the offset recess 34 to provide passage for a fastener by which the cylinder is fastened into the padlock casing.

Preferably the fastener comprises a countersunk head screw 37 and the recess 17 is adapted by the inclusion of a conical recess to accommodate the screw head; the screw shank passing through the aperture 36 to engage in a threaded recess within the cylinder to retain the cylinder within the combined recesses. Preferably, the screw is threadforming and forms a thread in the cylinder when it is inserted thereby precluding the need for a tapped hole in the cylinder, which otherwise must be provided.

In preferred embodiments, the shackle is easily removed from the body. In these embodiments the cam includes an additional release recess 38, as shown in Fig 5, similar to the unlocking recesses and having a configuration such that when the second locking ball 24 is in the release recess, the second ball is enabled to completely withdrawn from the longer shackle, i.e. completely withdrawn from the peripheral recess in the longer leg to thereby release the shackle and enable it to be removed from the body.

In preferred embodiments, the cam 25 includes a first cam portion comprising a substantially cylindrical portion having a curved side surface defined by a longitudinal axis coaxial with the cam axis of rotation, and a substantially circular first end face 40 adjacent to the closed end of the central recess 33 and an opposed second cam end 41; the axis of 25 rotation being substantially parallel to and between the longitudinal axii of the first and •.longer casing recesses in the casing.

In preferred embodiments, the first cam portion includes the first unlocking recesses 27 and the second unlocking recess 28 and the release recess 38. These 3 recesses are disposed within the curved side of the first cam portion and preferably comprise partial cylindrical concave surfaces which extend from the first end face towards the second cam end 41 and for a length that provides free movement of the balls into their respective recesses.

The recesses 27, 28, and 38 may be formed by advancing a rotating cutter blade Sinto the partially made cam from the first end face, said the cutter having an axis of rotation parallel with that of the cam axis of rotation and a periphery which overlays the 12 cam. Preferably the diameter of the cutter is substantially the same as the diameter of the locking balls described below.

In preferred embodiments, as shown in Fig 5, the first cam portion is integrally connected to a cam drive portion 42 having a second end face 43 disposed towards the inner end 44 of the cylinder barrel 45 as shown in Fig 20. The cam drive portion 42 has at least one drive recess (radially disposed from the cam axis of rotation) and preferably two opposed drive recesses 48, 49 extending from the second end face 43 towards the first end face 40, each said drive recess having a floor defined by a plane orthogonal to the axis of rotation of the cam and a side wall and in forms having the pair of drive recesses 48 and 49, the side walls comprise walls 5 1, 52 respectively, each side wall having a drive shoulder at one end and a stop drive shoulder at the other end and in forms having the pair of side walls, the cam has drive shoulders 67, 68 and stop drive shoulders 67A 68A corresponding with the side walls 51, 52 (and hence the drive recesses 48 and 49) respectively.

The drive portion further includes a bridge portion defined in part by the side wall of each drive recess and having opposed peripheral end walls comprising cylindrical portions to support a disc-like stop member which has an aperture of substantially circular cross-section interrupted by a finger associated with each drive recess, each said finger inwardly protruding into its associated drive recess to be engageable with the drive shoulder associated with the drive recess and wherein each finger abuts a drive shoulder when the cam is in the unlocking configuration shown in Figure 11.

S. As shown in Fig 6, commencing at the floor of each drive recess 48 and/or 49, and extending towards the first end surface 40, and having an axis parallel to that of 2 the cam, is an elongated additional pin recess 73, positioned as shown in Fig 15, such that in the locking configuration of the cam, the axis of each of these recesses 73 is Scoaxial with an axis of a pin recesses 54 in the barrel when the barrel is in the undisplaced, key removal configuration. Preferably, the diameter of the additional recesses is substantially the same as the diameter as the pin recesses 54.

In some forms, the drive portion 42 is substantially cylindrical in form but of reduced cross-sectional diameter so as to accommodate a torsional spring 47 which is supported around the drive portion and within the general diameter of the-central recess Each drive recess may be manufactured by advancing a rotating cutter blade into the partly made cam from the second end face 43 towards the first end, said cutter having San axis of rotation parallel with that of the cam and a periphery which overlays the cam 13 and when manufactured in this manner, each drive recess is a partial cylindrical in shape so the bridge 50 (disposed between them) is fan shaped.

As shown in Fig 20 and 22, projecting from the surface of the inner end 44 of the barrel towards the key entry end 53 of the barrel, is a pin recess 54 associated with each drive recess each having an axis parallel to that of the barrel. Within each barrel pin recess 54 is a longitudinally elongated drive pin 57 that include a portion that extends towards the cam.

In a padlock configured as a Type 1 padlock, each drive pin is configured to effect a first coupling mode by extending towards the cam to extend into a drive recess and in the preferred embodiment having opposed drive recesses drive pins extend into the drive recesses 48 and 49 to longitudinally overlap the respective drive shoulders 67 and 68 but not so far as to engage in an additional pin recess 73 in the cam this arrangement operably coupling with free movement the cam to the barrel.

In a padlock configured as a Type 2 padlock, each drive pin is configured to effect a second coupling mode by extending towards the cam to extend into a drive recess and to engage in an additional pin recess 73 in the cam and in the preferred embodiment having opposed drive recesses, a pair of opposed drive pins project into an opposed pair of additional recesses in the floors of the opposed drive recesses this arrangement operably coupling without free movement the cam to the barrel.

By simply changing the length that each drive pin protrudes into the cam, the padlock can be reconfigured between a Type 1 and Type 2 padlock.

In both types of padlock the barrel and cam can be said to be operably coupled by coupling means.

In preferred embodiments adjacent to the inner end 44 of the barrel is a disc-like 25 member 55 (comprising a pin holder) having a drive pin aperture 56 coaxial with each drive but of small diameter than the general diameter of the drive pin. Each drive pin aperture has a parallel sided elongation so as to extend the recess to the periphery of the disc-like pin-holder. Within the length of each drive pin is one and preferably multiple annular surface recesses engageable with the pin apertures 56 in the pin-holder such that S 30 when a pin is supported within the pin-holder by an annular recess and these members are supported within the padlock casing with the pin-holder supported between the barrel and cam, each drive pin is restrained from longitudinally displacing.

In a padlock configured as a Type 1 padlock, each drive pin in relation to the pin- S holder is configured such that the portion that extends towards the cam extends into a drive recess but not so far as to engage in an additional pin recess 73 in the cam.

14 In a padlock configured as a Type 2 padlock each drive pin in relation to the pinholder is configured such that the portion that extends towards the cam extends into a drive recess then further to engage in an additional pin recess 73 in the cam to directly couple the cam to the barrel without significant free movement.

By simply configuring the length that each drive pin protrudes from the disc-like pin holder (by engaging the appropriate drive pin annular groove within the pin aperture of the disc-like member), the padlock can be reconfigured between a Type 1 and Type 2 padlock. Each recesses within the disc-like member is configured such that when an annular recess is with the plane of the disc-like member, the drive pin can be assembled to the pin holder by radially displacing it from the vicinity of the periphery to be coaxially aligned.

Additionally, this embodiment of the drive pin enables a shorter cylinder to be employed by providing a spacer between the barrel and cam, as shown in Fig 25. The spacer is provided by a pair of spaced pin-holders assembled within the length of the drive pins; a first disc to be adjacent the interior end of the cylinder barrel 44, a second disc to be adjacent the cam and the drive pins would protrude from the second disc to provide either a Type 1 or Type 2 padlock. Each drive pin would preferably have multiple annular grooves to enable the members to be assembled to provide different padlock types while accommodating different cylinder lengths.

In another preferred embodiment as shown in Fig 5 to 8 and 20, projecting from the surface of the inner end 44 of the barrel towards the key entry end 53 of the barrel, is one and preferably two pin recesses 54 each having an axis parallel to that of the barrel.

Adjacent to the inner end 44 is an alternative disc-like pin-holder 55 having a pin aperture coaxial with each pin recess 54 but of smaller diameter. Within the barrel is at least 25 one and preferably two, longitudinally elongated drive pins 57, each drive pin having S. passage through the pin-holder to comprise a pin extension 58 which extends from the pin-holder 55 towards the cam. Preferably, at the point of intersection with the member each pin reduces in diameter to the diameter of the apertures 56 to be restrained by member 55 from displacing towards the cam. Preferably the drive pins 57 and member 30 comprise a separate sub-assembly 59, which in practice is inserted into the barrel as one.

The pin extension is a shorter length than the balance of the pin by a given distance.

S"In a first coupling mode, each drive pin extension extends towards the cam to extend into a drive recess to longitudinally overlap an associated drive shoulder and in the Spreferred embodiment having opposed drive recesses, a pair of opposed drive pins project into opposed drive recesses 48,49 to overlap drive shoulders 67 and 68 this arrangement operably coupling with free movement the cam to the barrel so that the barrel may be turned to angularly displace the cam.

The cam torsion spring 47, surrounding the drive portion of the cam has a moveable end 60 held in one of the drive recesses to abut a portion of the associated drive shoulder and a fixed end 61 projecting into the offset recess to abut a portion of the offset recess wall. It is configured to bias the cam away from the unlocked configuration and towards the locking configuration. Alternatively, the end 60 comprises a spring return which extends are short distance in a direction parallel to the axis of the cam to mate in a recess commencing at the floor of a drive recess and extending towards the first end surface.

A stop means 62 is included in the cam assembly to control cam rotation and amongst other things, to prevent the cam from being rotated by the spring in a (locking) direction from the (locked) configuration, i.e. too far in the locking direction and also to restrain the cam from being rotated by the barrel in an unlocking direction from the unlocked configuration; i.e. too far in the unlocking direction.

Preferably, the stop means comprises the substantially annular member 63 described above that straddles the bridge 50 to be supported by the bridge to be relatively angularly displaceable with respect to the cam.

Preferably the cam comprises a sub-assembly of components where the spring is retained between the first cam portion of larger diameter and the stop member 63 that is itself retained coaxially about the bridge 50 by a circlip 64 located towards the second end face 43 of the cam, the circlip locating behind a raised annular shoulders of the bridge.

In the locked configuration the spring biases the cam in a direction towards the locking configuration (away from the unlocking configuration of the cam) and with 25 reference to the accompanying drawings when viewing the cam from above, clockwise is defined as the locking direction.

The disc-like stop member 63 has the at least one substantially radially inwardly projecting finger (also called wedges) projecting into a drive recess, as described above, and in a preferred embodiment it has a pair of fingers 65 and 66, each locating one in each drive recess 48, 49 and an outwardly projecting stop 66A that protrudes into the *a offset recess.

The cam and stop are configured such that when the cam is in the locking configuration, as shown in Fig 13 to 16, each wedge to restrain the cam from rotating in a Sclockwise direction while the stop itself is restrained from rotating clockwise by the projecting stop that abuts a first wall 69 of the offset recess; (in preferred embodiments, a finger abuts drive shoulder 67 of the wall 5 1 associated with the drive recess 48 and a finger abuts drive shoulder 68 of the wall 52 associated with the drive recess 49) In the locked configuration of Figure 15, where the barrel is undisplaced, each drive pin protrudes longitudinally one into each drive recess to be adjacent the corresponding finger, and to be engageable with the finger.

Rotation of the barrel, as shown in Fig 9 to 12, in an anticlockwise direction from the locked configuration causes each drive pin to engage the adjacent wedge to urge the stop member 63 and stop portion 66A to rotate in an anticlockwise direction but in so doing each finger simultaneously engages a drive shoulders to cause the cam to rotate in an anticlockwise direction, and in practice the whole cam assembly rotates substantially simultaneously and the same amount in an anticlockwise direction until the stop shoulder 66A engages the opposite wall 70 of the offset recess; this latter configuration corresponding to the unlocking configuration of the cam.

When the cam is in the unlocking configuration and the shackle is open as shown in Fig 9 to 12, the second ball occupies both the peripheral recess and the second unlocking recess in the cam to prevents the cam from angularly displacing.

In the Type 1 padlock the key must then be reversible to the key withdrawal, (undisplaced position) while the cam remains displaced. To enable the key and barrel to displace while the cam remains restrained free movement is required between the barrel and cam. This is provided by each drive recess being configured to have free space to accommodate this displacement of each drive pin while the cam remains displaced -restrained by the second ball; and in the case of the preferred embodiment, there is free space 71 within drive recess 48 and free space 72 within drive recess 49.

Referring to Fig 11, we can see that in the unlocking configuration of the cam, the 25 free space lies between each drive pin and its associated stop shoulder the free space enabling the barrel and each drive pin to be rotated to the undisplaced position without causing a drive pin to engage a stop shoulder to urge the cam to rotate.

te Preferably, the Type 1 padlock includes a compression spring 18A supported in the longer recess 18 and employed to outwardly bias the longer shackle leg. It has a free length requiring it to be compressed when the shackle is inserted in the casing.

O*eo In a Type 2 padlock, when the cam is in the unlocked position the second ball occupies both the peripheral recess and the second unlocking recess in the cam to prevents the cam from angularly displacing and because there is no free movement between the cam and barrel, the barrel cannot be rotated to the key withdrawal position. between the cam and barrel, the barrel cannot be rotated to the key withdrawal position.

When the cylinder is removed from the padlock by use of the control key or removal of the screw according to which cylinder is employed, the cam may be rotated in an unlocking direction an additional amount and until the release recess 38 aligns with the second ball this recess being sufficiently deep to allow the second ball to withdraw completely from the longer shackle thereby enabling the shackle to be removed from the body, as shown in Fig 1 to 4 A hand tool, such as pliers, is used to displace the cam anti-clockwise (against the action of the spring) in the unlocking direction from the unlocked configuration while the stop member 63 remains undisplaced with the stop portion 66A abutting wall 70. The cam can be so rotated till each finger abuts a stop shoulder, to prevent the cam from being further rotated, this cam configuration corresponding to the release configuration of the cam. In the embodiment having opposed drive recesses shown in Fig 1 to 4, the release recess is angularly disposed such that the cam is displaced until the end shoulders 67A and 68A engage the wedges 65 and 66 simultaneously to restrain the cam from rotating further in an anti-clockwise direction.

The drive recesses 48 and 49 may be formed by advancing a rotating cutter blade having an axis of rotation parallel with that of the cam and which overhangs the drive portion 42 from the second end face 43 towards the first end face. Preferably the annular stop member 63 comprises a metal pressing.

Many variations of the above-described embodiments also come within the scope of the invention, including: the padlock cam having a single drive recess, a single drive pin, and a single drive shoulder.

the padlock cam having a pair of drive recesses, a pair of drive pins, and a pair of 25 drive shoulders, the cam being without a release recess, the Type 2 padlock being without a torsion spring, and the padlock being configured to employ a cylinder of other cross-section In preferred embodiments, at least one of the shackle locking recesses comprises 30 a portion or portions of surfaces of revolution in which the axis of revolution defining the I* l surface intersects the body of the shackle and where the surface of the recess extends in all directions from the axis. Preferably the axii of tile aforementioned surfaces are parallel and preferably a plane through the axii also intersects the longitudinal axis of the shackle.

The first and second locking recesses preferably comprise a portion or portions of surfaces of revolution as described above. Alternatively, the second locking recess 18 comprises two such portions located adjacently a small distance apart and joined by a channel portion.

The longitudinally elongated recess preferably comprises a channel defined by a uniform cross-section.

Preferably, each of the surfaces of revolution are spherical and are defined by a radius and preferably this radius is substantially the same as the radius of the balls.

Preferably the cross-section of the longitudinally elongated channel is defined by a radius and preferably this radius is substantially the same as that of the radius of the balls.

It is envisaged that this improved shackle construction be employed in all types of padlocks including the configurations described below. It should also be noted that the invention described in relation to shackles is not limited to padlocks and are applicable to all types of locks.

Configurations envisaged include: a padlock employing only a first locking recess and first ball, a padlock employing only a second locking recess and second ball, a padlock where the shackle comprises a cable connected to a solid cylindrical end portion having a first locking recess and the other end is secured to the padlock body, a padlock where the shackle comprises a cable connected on one end to a solid cylindrical end portion having a first locking recess and the other end is connected to a solid cylindrical end portion having a second locking recess, a padlock where the shackle comprises an elongated member having a first locking recess.

•--The preferred shackle may be manufactured by turning bar on a lathe or similar 25 machine tool to produce a shackle blank 74, as shown in Fig 23, having chamfered or o. radiused ends and the peripheral recess. The first and second locking recesses are formed by advancing a rotating cutter tool 75, preferably having a spherical end 76 defined by a radius similar to that of the ball into the shackle blank or partly manufactured shackle, to manufacture a recess having a surface comprising a surface of revolution.

30 In an alternative embodiment, the second locking recess is constructed firstly by advancing a cutter into the shackle blank as described above and then advancing it a short distance, while it is cutting, longitudinally along the shackle blank.

The longitudinal recess may be manufactured by manufacturing the second locking recess and then withdrawing the cutter partly from the formed second locking recess and advancing it, while it is cutting, longitudinally along the shackle blank towards the peripheral recess till the cutter is aligned with peripheral recess. Preferably the cutter tool has a spherical end defined by a radius similar to that of the ball.

Preferably the axis of the cutter tool lies in the same plane as the longitudinal axis of the shackle blank.

After machining, the shackle blank is aligned so that the plane in which the axii of the surfaces of revolution lie is orthogonal to the axis of an angularly displaceable mandrel 77 about which the shackle will be formed, as shown in Fig 24 the mandrel being supported on a shaft 77A. The shackle blank 79 is retained adjacent the cylindrical mandrel with the axii pointing towards the mandrel and the junction between the first leg and joining portion touching the side of the mandrel. A roller 78 is located on the other side of the shackle blank so that the shackle blank is between the roller and mandrel and touches both. The mandrel adjacent the shackle blank has a tangential extension comprising a holding block 80 which has an aperture in which to support a leg portion of the shackle and a lever portion 8 1. The shackle is retained in the aperture by a fastener.

Rotation of the lever causes the mandrel and attached block to rotate around the mandrel axis of rotation, while the roller remains fixed but free to rotate, to form the shackle blank in a shape corresponding to the mandrel. In this way the shackle blank is formed to have parallel legs.

Preferably, the first leg which is retained in the block comprising part of the mandrel. Preferably the aperture has a cross recess through which a spherical headed fastener has passage to be displaced firmly into the first locking recess of the shackle blank. Preferably, the surfaces of the roller and cylindrical portion of the mandrel, where V'64 they contact the shackle body, comprise recesses having a semi-circular cross-section 82 .0 S.:o defined by a radius substantial the same as the radius of the shackle body.

25 The removable cylinder has a number of transverse pin chambers in the cylinder housing each extending from a portion of the outer surface of the housing to meet coaxially with a pin chamber in the barrel when the key is removed. The longitudinal axii of the chambers are substantially on the same plane when the key is withdrawn. The apertures in the surface where the recesses intersect the surface are plugged to prevent 30 the pins and other components from escaping.

Commonly each aperture is plugged with an individual cylindrical plug but preferably the casing between the apertures is connected by a channel which extends to S•the inner end of the casing and preferably the plug comprises a strip of resilient material a such as plastic which occupies the channel and that has substantially cylindrical extensions which extend into each pin chamber. Preferably the extensions are radially compressible and, in-part at least, are of a diameter slightly larger than the chambers so that after being pressed into the chambers they exert a radial force on the walls of the chambers -the chambers in turn exerting a reactionary force on the extensions to retain the extensions within the chambers. When re-pinning is required the strip can be quickly peeled from the cylinder to provide access to the chambers and then quickly reapplied.

This means of capping pin apertures is applicable to all pin cylinders, (not just that described herein), in which the apertures are inaccessible once the cylinder is installed into the padlock or lock in which it is employed.

Throughout this specification and claims that follow, unless the context requires otherwise, the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers.

Throughout this specification and claims that follow, unless the context requires otherwise, the positional prepositions such as rear, forward are used to assist in description of the preferred embodiments and have in general no absolute significance.

The term "coupling means" is not intended to be limited to the forms employed in the embodiments and description herein but is to be interpreted as including any forms of coupling which would be readily apparent to the skilled in the art.

•*g oo go• oo* ooo* o** **o *go **go **o o•* ooooo