WO2011091474A1

WO2011091474A1 - Flexible lock

Info

Publication number: WO2011091474A1
Application number: PCT/AU2011/000086
Authority: WO
Inventors: Malcolm Mckechnie; Hugo Davidson; Kynan Taylor; Chris Bilanenko
Original assignee: Knog Pty Ltd
Priority date: 2010-01-28
Filing date: 2011-01-28
Publication date: 2011-08-04
Also published as: CN203113965U; DE202011110085U1

Abstract

A flexible lock having at least two end formations and an elongated flexible member there-between for allowing the locking of the two end formations together and the flexible lock further including a flexible continuous covering enclosing substantially the entire flexible lock.

Description

FLEXIBLE LOCK

Field of the Invention

This Invention relates to a flexible lock and in particular to a new form of cable lock.

Whilst the invention can be applied to flexible locks used for a range of purposes, for convenience sake it shall be described herein in terms of a cable lock for use in securing bicycles.

Background to the Invention

A cable lock is one form of flexible lock that includes a lock tiousing at one end of a flexible member and a lock pin at the other end wherein the lock pin fits into the lock housing and can be releasably locked therein. Locking can be by means of a key lock in which a key is used in a key barrel, a combination lock in which multiple pins can be separately aligned in combination to form a single possible opening combination from large possible number of multiple choices, or other lock mechanism. The importance of a flexible lock is the security it provides when new and over time and this includes not only the lock material but also the mechanism and also the construction.

Generally the flexible member needs to be a material that is not readily cut. This is where a cable of certain minimum diameter is a common means of forming a flexible lock and therefore the prevalence of cable locks. Clearly other types and forms of material for flexible members can be used, including chains

Therefore throughout this specification "flexible lock" is to be understood to include cable locks and chain locks and any other flexible member that has through choice of material or construction a strength which limits or hinders the chance of cutting through the flexible member.

The mechanisms of locking members bf a flexible lock are also important However such is not in question in the current design and any form of acceptable locking mechanism can be used. The construction of flexible locks is also important to improve security. Generally the cable is crimped to the body of the locking housing and lock pin. However a collar is needed to be fitted over the crimping points and over part at least of the lock housing to not allow access to the crimping points or to show any wear points. Similar fitting is required at the end of the lock pin. This construction results in two large bulbous end pieces with an elongated cable therebetween.

It is therefore further necessary to cover the cable. This is usually by a tubular plastic covering. However this covering also needs to be held by the bulbous end pieces, which further increases their size. Overall there are a number of parts that if all are not fitting correctly or wear and tear occurs can result in ready sliding and revealing of components and connections and thereby sudden decrease of the effective security of the cable lock. It can therefore be seen that there are a number of disadvantages of current designs of cable locks. Accordingly, it is an object of the present invention to overcome or substantially ameliorate one or more of the disadvantages of the prior art.

Summary of the Invention

The present invention provides a flexible lock having a lock housing and a lock pin receivably lockable into the lock housing, an elongated flexible member with the lock housing and lock pin mounted at or near relative ends of the elongated flexible member, and the flexible lock further includes a flexible continuous covering extending from the lock pin to the lock housing and engagingly covering the flexible member and attachments to the lock housing and the lock pin.

The elongated flexible member can include a core of plurality of microfilament cables each including at least one fibre core with a plurality of smaller diameter metal cables mounted circumferentially to a respective fibre core

The continuous covering can substantially cover the lock housing and the body of the lock pin while allowing for protrusion of the locking lug.

Preferably the continuous covering is formed by a plastics material shrink fitted over the flexible member and attachments to the lock housing and the lock pin to provide the engaging covering. The continuous covering is more preferably obtained by overmoulding a settable flexible material that sets onto the flexible lock to prevent access to the components thereof but allows flexibility of the flexible lock. The overmould can be a silicone overmould.

In one particular form of the invention there is provided a flexible lock having a lock housing and a lock pin receivably lockabie in the lock housing and having a continuous outer covering with a substantially continuous surface devoid of edges except for the ends, with the protrusion of the locking lug of the lock pin at one end and the end of the lock housing at the other, and further devoid of edges except for the accessibility to the locking mechanism of lock housing and the receiving aperture of the lock housing for receiving the locking lug of the lock pin. The continuous outer covering can Include a shape that has two elements, a first constant cross section elongated tubular section and a second bulbous form wherein the bulbous form is connected by a continuous curve from the tubular section and has a diameter substantially no greater than about twice the diameter of the tubular section.

The bulbous section preferably has a length greater than its diameter with a substantially continuous outer curve from the connecting tubular section to a maximum diameter and reducing to a smaller end diameter. In accordance with another aspect of the invention there is provided a method of forming a flexible lock such as a cable lock including the steps of:

a. providing a locking means with a first plug means and a second socket means for receiving the first plug means and with a lock to selectively lock the plug means in the socket means; b. connecting each end of an elongated cable to one of the first plug means and the second socket means of the lock means; c. maintaining locating pins at the second socket means and the lock means:

d. providing an overmould over the entire article except for the at the location of the locating pins and the end of the first plug means;

whereby a cable lock is formed having a length of flexible cable and a means for locking relative ends to form a closed loop around the article and/or fixing means, the cable lock further including an overmoulded continuous cover extending from lacking plug to locking socket with openings for the three elements of locking plug and socket and lock. The method of providing the overmould can include providing a tool having an upper and lower tool forming a cavity therebetween that closely follows the outer shape of the components of the flexible lock but provides an outer shaping of two elements, a first constant cross-section elongated tubular section and a second bulbous form. The tool is able to receive the inner elements of lock pin crimped to one end of cable and lock body crimped to other end. The lock pin protrudes from the tool. Plugs are positioned at the other openings to receive the locking pin and to allow access to the key lock. By insertion of settable flexible material into the mould the bulbous form is created with a continuous curve from the tubular section and has a diameter substantially no greater than about twice the diameter of the tubular section. The bulbous section preferably has a length greater than its diameter with a substantially continuous outer curve from the connecting tubular section to a maximum diameter and reducing to a smaller end diameter.

It can be seen that invention provides an Improved flexible lock that is secure while being more streamlined. Overmoulding in continuous form from locking plug to locking socket provides slim continuous outer covering with merely openings for the three elements of locking plug and socket and lock activation means and avoids secondary covering over cable and secondary crimping bulges joining end of secondary cover to locking plug and socket respectively

The benefits of the invention can be considered to be provided by one or more of the following:

• The flexible continuous covering forming a single entity such that it is providing a visual barrier that prevents viewing of any connection points or other attackable parts of the components therein.

• The flexible continuous covering being engagingly covering the flexible member and connections to the lock housing and lock pin so there is more than one or two attachment points that could fail and provide access to inner components and therefore decrease security of the flexible lock. Instead there is continuous attachment and therefore increased security;

The flexible continuous covering forming a continuous smooth surface so as to decrease risk of snagging on components of the bicycle or other article being locked so as to decrease damage to and decrease damage to flexible lock;

The flexible continuous covering engagingly connected to components therein so as to minimise Internal friction which causes internal wear points and align flexibility of flexible member to the covering to ensure single article; and ♦ The elongated flexible member includes a core of plurality of microfilament cables each including at least one fibre core with a plurality of smaller diameter metal cables mounted circumferentially to a respective fibre core and thereby together with the flexible outer layer restricts cutting. Brief Description of the Drawings

In order that the invention can be more readily understood an embodiment will be described by way of non-limiting example with reference to the drawings wherein:

Figure 1 is a diagrammatic rear view of a flexible lock in accordance with one embodiment of the invention in a looped locked position;

Figure 2 is a diagrammatic view of the flexible lock of Figure 1 in an unlooped unlocked position;

Figure 3 is a diagrammatic front view of the flexible lock of Figure 1 in a looped locked position showing the lock key-entry point;

Figure 4 is a detail cross section of the flexible lock of Figure 1 in a looped unlocked position showing the mechanism being protected by the overmould with lock pin lug in line for receipt in side opening of lock;

Figure 5A, 5B and C are diagrammatic internal view, external view and end view of a flexible lock in the form of a cable lock in accordance with a first embodiment of the Invention;

Figure 6 is a diagrammatic view of a mould tool for use in forming the flexible lock components of Figure 1A into the completed article of Figure 5B;

Figure 7 is a diagrammatic view of the flexible lock of Figure 1 in a unlooped unlocked position;

Figure 8 is a diagrammatic cross-sectional detail of the central portion of the flexible lock of Figure 7; and Figure 9 is a diagrammatic view of an attack on the diagrammatic cross- sectional detail of the central portion of the flexible lock of Figure 8.

Description of a Preferred Embodiment of the Invention

Referring to the drawings and particularly Figures 1 to 4 there is provided a flexible lock 21 having a lock housing 23 and a lock pin 22 receivably lockable into the lock housing, an elongated flexible member with the lock housing and lock pin mounted at or near relative ends of the elongated flexible member. The elongated flexible member includes a core of plurality of microfilament cables 24m each Including at least one fibre core 24f with a plurality of smaller diameter metal cables 24g mounted circumferentially to a respective fibre core. The core of microfilament cables with the central fibre core and a plurality of the microfilament cables are braided around the central fibre core.

The elongated flexible member of the flexible lock further includes a flexible continuous covering 31 extending from the lock pin to the lock housing and engagingly covering the flexible member and attachments to the lock housing and the lock pin and thereby covers the lock housing and the body of the lock pin while allowing for protrusion of the locking lug. The continuous covering is formed by an overmould which is a silicone overmould over the flexible member and attachments to the lock housing and the lock pin.

This provides a lock housing and a lock pin receivably lockable in the lock housing and having a continuous outer covering with a substantially continuous surface devoid of edges except for the ends, with the protrusion of the locking lug of the lock pin at one end and the end of the lock housing at the other, and further devoid of edges except for the accessibility to the locking mechanism of lock housing and the receiving aperture of the lock housing for receiving the locking lug of the lock pin. The flexible lock loops from a substantially flat unlocked position to a single loop locked position.

Referring to Figures 5 and 6, in this preferred embodiment, the invention provides a flexible lock 21 in the form of a cable lock having a lock housing 23 and a lock pin 22 receivably lockable into the lock housing. An elongated flexible member 24 in the form of a small diameter such as 10 millimetre diameter steel cable extends between the lock housing 23 and lock pin 22 mounted al relative ends of the elongated flexible member 24.

The lock pin 22 has a body 22b with a collar means on one side forming a crimping connection 22c around one end of the flexible cable 24. On the opposite side of the body extends a lock pin lug 22a in the form of a pyramidal circular head on a narrower neck portion.

The lock housing 23 comprises a generally barrel construction body 23b able to receive a key barrel 23d through a longitudinal end and which Is able to lock the lock pin lug 22a In the barrel when received through a side opening 23a. The lock housing 23 at the other end of the body 23b to the key barrel 23d has a crimping connection 23c for grabbing around the other end of the flexible cable 24. The flexible lock 21 further includes a flexible continuous covering 31 extending from the lock pin 22 to the lock housing 23 and engagingly covering the flexible member 24.

The continuous covering 31 can substantially cover the lock housing 23 and the body of the lock pin 22b and crimp attachments 23c, 22c of the lock housing and the lock pin to the flexible member while allowing for protrusion of the locking lug 22a. In particular the continuous outer covering 31 has a substantially continuous surface devoid of edges except for the ends 32, 33, with the protrusion of the locking lug 22a of the lock pin at one end 32 and the key end 23d of the lock housing at the other, and further devoid of edges except for the accessibility to the locking mechanism of lock housing and the receiving aperture 23a of the lock hosing for receiving the locking lug 22a of the lock pin.

The continuous covering 31 is obtained by overmouldlng a settabie silicone material that sets onto the flexible lock to prevent access to the components thereof but allows flexibility of the flexible lock. As shown in Figure 3 this is achieved by providing a moulding tool for holding a locking means with a first plug means and a second socket means which in use can receive the first plug means and with a lock selectively lock the plug means to the socket means. Each end of a cable is connected to one of the first plug means and the second socket means of the lock means. Locating pins are maintained at the second socket means and the lock and the settabie material is inserted into the mould which provides an overmould over the entire article except for at the location of the locating pine and the end of the first plug means. in this way a cable lock 21 is formed having a length of flexible cable 24 and a means for locking relative ends to form a closed loop around the article and/or fixing means with an overmoulded continuous cover 31 extending from locking lug 22a to locking body 23 with openings 32, 33, 34 for the three elements of locking lug 22a and socket 23a and key lock 23d. Referring to Figures 7, 8 and 9 there is shown use of an inner braided steel cable that has a fibrous core, around which individual braided steel cables are wound. The overmould surrounds the combination. The purpose of this is to increase the security of the cable, as it takes considerably longer to cut through with conventional bolt cutters for at least the following reasons:

1. The fibre core is soft and hence allows the cable to deform/squash (as a whole) when pressure is applied - usually in the form of a bolt cutter type implement, reducing the effectiveness of this type of cutting implement 2. The fibre core itself is harder to cut through using a bolt cutter type implement that does not have sharpened blades

3. More than one cutting implement is probably required and therefore decreases likelihood of break in security.

Instead of simply using steel cable - which Is generally no match for a decent set of bolt cutters - the flexible locks include a core of microfilament cables. Any lock can eventually be cut. Security is based on making it more difficult and time consuming and therefore less likely to be penetrated. But the Invention uses a small diameter such as 10mm or 12mm braided, loose-bound, inner steel cable with a 'fibre core' in the middle that makes it difficult for bolt cutters to get through. It will take a thief a substantial more time to cut through this than other locks with only steel cables, and this is a major theft deterrent. The Idea as shown in Figure 9 is that the microfilaments are strong enough to maintain the lock's integrity under attack whilst at the same time being too thin to easily cut with a blunt Instrument such as a set of cutters. This construction can offer another 40-60 seconds of protection over comparable cables from other manufacturers.

While we have described herein a particular embodiment of a flexible lock, it is further envisaged that other embodiments of the invention could exhibit any number and combination of any one of the features previously described. However, it is to be understood that any variations and modifications which can be made without departing from the spirit of the Invention are included In the scope thereof. In one form the flexible lock has a seamless overmould using medical grade UV stable silicone. This covers a braided loose bound steel cable with fibre core (making cable more secure in the event of bolt cutter attack). It has 3 Colour coded overmoulded keys with wrist coll and with 1000 combination blade style lock cylinder stainless steel locking shackle. Due to its construction there are no leverage points. In one form the cable diameter is about 22mm with steel cable diameter of 12mm. Total length is about 880mm with weight of about 1kg. It is non marking and scratch surface resistant. It can be mounted to a bicycle by a tool-less bike mount attachment. The medical grade bright red seamless silicone cover will not scratch the bike frame.

Claims

1. A flexible lock having at least two end formations and an elongated flexible member therebetween for allowing the locking of the two end formations together and the flexible lock further including a flexible continuous covering enclosing substantially the entire flexible lock.

2. A flexible lock according to claim 1 wherein the elongated flexible member is joined to the at least two end formations within the body of the two end formations and wherein the flexible continuous covering provides a streamlined outer product.

3. A flexible lock according to claim 1 or 2 wherein the flexible lock having a lock housing and a lock pin recelvably lockable into the lock housing, an elongated flexible member with the lock housing and lock pin mounted at or near relative ends of the elongated flexible member, and the flexible lock further including a flexible continuous covering enclosing substantially the entire flexible lock including lock pin, the lock housing and the flexible member therebetween.

4. A flexible lock according to any one of the preceding claims wherein the elongated flexible member includes at least one fibre core with a plurality of smaller diameter metal cables mounted circumferentially to a respective fibre core.

6. A flexible lock according to any one of the preceding claims wherein the elongated flexible member includes a core of plurality of microfilament cables each Including at least one fibre core with a plurality of smaller diameter metal cables mounted circumferentially to a respective fibre core.

6. A flexible lock according to any one of the preceding claims wherein the elongated flexible member includes a core of microfilament cables with a central fibre core and a plurality of the microfilament cables braided around the central fibre core.

7. A flexible lock according to any one of the preceding claims wherein the lock loops from a substantially flat unlocked position to a single loop locked position.

8. A flexible lock according to any one of the preceding claims wherein the lock loops from a multiple looped unlocked position to a multiple looped locked position.

9. A flexible lock according to any one of the preceding claims wherein the continuous covering substantially covers the lock housing and the body of the lock pin while allowing for protrusion of the locking lug.

10. A flexible lock according to claim 3 wherein the continuous covering is formed by a plastics material shrink fitted over the flexible member and attachments to the lock housing and the lock pin to provide the enclosing covering.

11. A flexible lock according to claim 3 wherein the continuous covering is formed by a thermo-plastic polymer over the flexible member and attachments to the lock housing and the lock pin to provide the enclosing covering.

12. A flexible lack according to claim 3 wherein the continuous covering is more preferably obtained by overmoulding a settable flexible material that sets onto the flexible lock to prevent access to the components thereof but allows flexibility of the flexible lock.

13. A flexible lock according to claim 12 wherein the overmould is a silicone overmould,

14. A flexible lock according to claim 3 having a lock housing and a lock pin receivably lockable in the lock housing and having a continuous outer covering with a substantially continuous surface devoid of edges except for the ends, with the protrusion of the locking lug of the lock pin at one end and the end of the lock housing at the other, and further devoid of edges except for the accessibility to the locking mechanism of lock housing and the receiving aperture of the lock housing for receiving the locking lug of the lock pin.

15. A flexible lock according to claim 14 wherein the continuous outer covering can include a shape that has two elements, a first constant cross section elongated tubular section and a second bulbous form wherein the bulbous form is connected by a continuous curve from the tubular section and has a diameter substantially no greater than about twice the diameter of the tubular section.

16. A flexible lock according to claim 15 wherein the bulbous section preferably has a length greater than its diameter with a substantially continuous outer curve from the connecting tubular section to a maximum diameter and reducing to a smaller end diameter.

17. A method of forming a flexible lock such as a cable lock Including the steps of:

a. providing a locking means with a first plug means and a second socket means for receiving the first plug means and with a tock to selectively lock the plug means in the socket means;

b. connecting each end of an elongated cable to one of the first plug means and the second socket means of the lock means;

c. maintaining locating pins at the second socket means and the lock means:

whereby a cable lock is formed having a length of flexible cable and a means for locking relative ends to form a closed loop around the article and/or fixing means, the cable lock further including an overmoulded continuous cover extending from locking plug to locking socket with openings for the three elements of locking plug and socket and lock.

18. The method of claim 17 wherein providing the overmould includes providing a tool having an upper and lower tool forming a cavity therebetween that closely follows the outer shape of the components of the flexible lock but provides an outer shaping of two elements, a first constant cross-section elongated tubular section and a second bulbous form.

19. The method of claim 17 wherein the tool is able to receive the inner elements of lock pin crimped to one end of cable and lock body crimped to other end; the lock pin protrudes from the tool; and plugs are positioned at the other openings to receive the locking pin and to allow access to the key lock.

20. The method of claim 17 wherein the elongated flexible member is joined to the at least two end formations within the body of the two end formations and wherein the flexible continuous covering provides a streamlined outer product

21. The method of claim 17 wherein by insertion of settabie flexible material into the mould the bulbous form is created with a continuous curve from the tubular section and has a diameter substantially no greater than about twice the diameter of the tubular section. The bulbous section preferably has a length greater than its diameter with a substantially continuous outer curve from the connecting tubular section to a maximum diameter and reducing to a smaller end diameter.

22. The method of claim 17 wherein overmoulding^' is in continuous form from locking plug to locking socket provides slim continuous outer covering with merely openings for the three elements of locking plug and socket and lock activation means and avoids secondary covering over cable and secondary crimping bulges joining end of secondary cover to locking plug and socket respectively.

23. The method of claim 17 wherein the elongated cable Is provided by a core of plurality of microfilament cables each including at least one fibre core with a plurality of smaller diameter metal cables mounted circumferentially to a respective fibre core.

24. A flexible lock according to claim 3 wherein flexible continuous covering forming a single entity such that it is providing a visual barrier that prevents viewing of any connection points or other attackable parts of the components therein.

25. A flexible lock according to claim 3 wherein the flexible continuous covering being engagingly covering the flexible member and connections to the lock housing and lock pin so there is more than one or two attachment points that could fail and provide access to inner components and therefore decrease security of the flexible lock. Instead there Is continuous attachment and therefore Increased security.

26. A flexible lock according to claim 3 wherein the flexible continuous covering forming a continuous smooth surface so as to decrease risk of snagging on components of the bicycle or other article being locked so as to decrease damage to and decrease damage to flexible lock.

27. A flexible lock according to claim 3 wherein the flexible continuous covering engagingly connected to components therein so as to minimise internal friction which causes internal wear points and align flexibility of flexible member to the covering to ensure single article.