ELECTRIC DOOR LOCK MECHANISM AND METHOD TO OVERRIDE

Abstract

A lock mechanism for a vehicle latch includes a cable link. Also included is a pawl release link, the cable link and the pawl release link switchable between an engaged condition and a disengaged condition, the engaged condition allowed manual release of the vehicle latch, the disengaged condition preventing release of the vehicle latch. Further included is an electrically driven gear operatively coupled to the cable link and the pawl release link to reset the cable link and the pawl release link to the disengaged condition.

Claims

1. A lock mechanism for a vehicle latch, the lock mechanism comprising: a release cable actuated by a handle available to a user; a cable end fitting disposed at an end of the release cable; a cable link defining an opening for receiving the release cable, the cable link retaining the cable end fitting therein, wherein tensioning of the release cable translates the cable link from a first position to a second position by overcoming a spring force applied to the cable link, the spring force biasing the cable link to the first position; a pawl release link selectively coupled to the cable link, the pawl release link and the cable link switchable between a coupled condition and a decoupled condition, the coupled condition resulting in corresponding translation of the cable link and the pawl release link, the decoupled condition resulting in independent translation of the cable link and the pawl release link; a release clutch pivotably coupled to the cable link and moveable between an unlocked position and a locked position, the unlocked position disposing the release clutch in contact with the pawl release link to couple the cable link and the pawl release link, the locked position decoupling the cable link and the pawl release link; and an electrically driven gear operative with the release clutch to electrically reset the release clutch to the locked position upon detection of a vehicle speed in excess of a threshold speed.

2. The lock mechanism of claim 1, further comprising a cam rotatable about a cam axis between a first cam angular position and a second cam angular position, the first cam angular position biasing the release clutch to the unlocked position, the second cam angular position biasing the release clutch to the locked position.

3. The lock mechanism of claim 2, further comprising a pawl rotatable about a pawl axis between a first pawl angular position and a second pawl angular position, the pawl having a contact surface and a second contact surface, the first contact surface contacted by the cable link moves from the first position to the second position of the cable link to rotate the pawl, the second contact surface engageable with a catch feature of the cam to retain the cam in the second cam angular position.

4. The lock mechanism of claim 3, wherein the pawl is spring biased in a first rotatable direction and the cam is spring biased in a second rotatable direction, the first and second rotatable directions opposite to each other.

5. The lock mechanism of claim 4, wherein the electrically driven gear is rotatable in the second rotatable direction about a gear axis.

6. The lock mechanism of claim 5, wherein the gear axis and the pawl axis are a common axis.

7. The lock mechanism of claim 5, wherein the electrically driven gear is driven by a worm of a worm gear arrangement, the worm driven by an electric motor.

8. The lock mechanism of claim 5, wherein movement of the cable link from the second position to the first position of the cable link allows rotation of the pawl toward engagement of the first contact surface and the catch feature of the cam, the gear rotating to bias the cam to position the catch feature and the first contact surface into engagement to reset the release clutch to the locked position.

9. The lock mechanism of claim 1, further comprising a switch located proximate the cable, the switch detecting movement of the cable link during movement between the first and second positions.

10. The lock mechanism of claim 9, wherein the switch is in a deactivated state when the cable link is in the first position and in an activated state when the cable link is in the second position.

11. The lock mechanism of claim 9, wherein the switch is located one-half of the distance between the first position and the second position.

12. The lock mechanism of claim 9, wherein the switch is in operative communication with a controller to indicate the position of the cable link, the controller in operative communication with the electrically driven gear to actuate movement of the gear to reset the release clutch.

13. The lock mechanism of claim 1, wherein the threshold speed ranges from 3 km/hr to 5 km/hr.

14. The lock mechanism of claim 9, wherein the threshold speed is 4 km/hr.

15. A lock mechanism for a vehicle latch, the lock mechanism comprising: a cable link; a pawl release link, the cable link and the pawl release link switchable between an engaged condition and a disengaged condition, the engaged condition allowed manual release of the vehicle latch, the disengaged condition preventing release of the vehicle latch; an electrically driven gear operatively coupled to the cable link and the pawl release link to reset the cable link and the pawl release link to the disengaged condition.

16. The lock mechanism of claim 15, further comprising a release clutch pivotably coupled to the cable link and moveable between an unlocked position and a locked position, the unlocked position disposing the release clutch in contact with the pawl release link to provide the engaged condition, the locked position decoupling the cable link and the pawl release link to provide the disengaged condition.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] The subject matter, which is regarded as the invention, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawing in which:

[0006] FIGS. 1-10 illustrate a door lock mechanism with a cable link and a pawl release link in various positions; and

[0007] FIGS. 11-26 illustrate a cam, a pawl and an electrically driven gear of the door lock mechanism in various positions.

[0008] The detailed description explains embodiments of the invention, together with advantages and features, by way of example with reference to the drawing.

DETAILED DESCRIPTION OF THE INVENTION

[0009] Referring to the Figures, a door lock mechanism for a vehicle door is illustrated. The door lock mechanism may be employed with numerous types of vehicle doors and vehicle latch assemblies. In some embodiments, the door lock mechanism is utilized with a vehicle door that is hinged on the rear side of the door, relative to the length of the vehicle. As described herein, the disclosed embodiments effectively decoupled a door latch release mechanism and provides a mechanical way to override the mechanism in the event of a power loss by double-pulling on the manual release handle. Under a normal operating condition, the lock mechanism will reset electrically after the first pull of the release handle, thus not allowing for a release event on the second pull of the handle. Normal operating condition refers to vehicle power being present and available and may also be referred to herein as a first operating condition. In the event of a disruption or loss of vehicle power (also referred to herein as a second operating condition), the electrical reset will not occur and the latch will be allowed to release manually upon the second actuation of the door handle.

[0010] Throughout the Figures, the door lock mechanism is generally referenced with numeral 10. Components are progressively discussed, with certain features omitted from some Figures to more clearly illustrate the structural and functional details of each component.

[0011] Referring to FIG. 1, a portion of the door lock mechanism 10 is illustrated. In particular, a pawl release link 12, a cable link 14, a cable end fitting 16, and a release cable 18 are shown. The pawl release link 12 and the cable link 14 slide linearly with each other and on the same plane, and in the same direction as the axis of the cable end fitting 16. The cable end fitting 16 is retained within the cable link 14. In particular, the cable end fitting 16 is positioned within the cable link 14 by extending through a slot or opening 19 defined by the cable link 14. The cable end fitting 16 may be any suitable shape that is sized to prevent withdrawal from the cable link 14 during tensioning of the release cable 18. The cable end fitting 16 drives the cable link 14 and, when coupled with the pawl release link 12, will release the system. The cable link 14 returns itself and the cable end fitting 16 to their initial position using a return spring. A cable conduit 20 is press fit into a tab 22 extending from a backplate 24. The cable conduit 20 remains static in this position through all positions and functions of the mechanism 10 described herein.

[0012] As shown in FIGS. 2 and 3, the cable link 14 is moveable between a first position (FIG. 2) and a second position (FIG. 3). The first position refers to a home position of the cable link 14 that is present in an initial state of the cable link 14. The second position refers to a released position and is shown at its full travel position away from the first position. The pawl release link 12 and the cable link 14 can move independently of each other. FIG. 4 shows the pawl release link 12 in an initial and final position and FIG. 5 shows the cable link 14 in an initial and final position (i.e., first and second position) of the cable link.

[0013] FIG. 6 illustrates a release clutch 30 operatively coupled to the cable link 14. In particular, a portion of the cable link 14 is disposed within a slot 32 of the cable link 14 and retained therein. The release clutch 30 is pivotable about the portion of the release clutch 30 disposed within the slot 32. The release clutch 30 is coupled between the cable link 14 and the pawl release link 12, and becomes loaded in shear when the cable link 14 is actuated. The release clutch 30 is selectively engaged with the pawl release link 12 due to the pivotable nature of the release clutch 30. Specifically, the release clutch 30 is pivotably between an unlocked position (FIG. 7) and a locked position (FIG. 8). As shown, the unlocked position is defined by a coupled relationship of the cable link 14 and the pawl release link 12 when the release clutch 30 is pivoted to be in engagement with the pawl release link 12. In this orientation, the release cable 18 is able to pull on the cable link 14 and drive the pawl release link 12 to release the latch, as shown by the two positions illustrated in FIG. 9. The locked position is defined by a decoupled relationship of the cable link 14 and the pawl release link 12 when the release clutch 30 is pivoted to be out of engagement with the pawl release link 12. In this orientation, the release cable 18 pulls on the cable link 14, without actuating the pawl release link 12, thereby not releasing the latch, as shown by the two positions illustrated in FIG. 10.

[0014] Referring now to FIG. 11, a cam 40, a pawl 42 and a gear 44 are illustrated. The cam 40 is used to control the state of the release clutch 30. The cam is naturally returned in the clockwise direction (in the illustrated perspective) with a return spring 46. The pawl 42 holds the cam 40 in a locked state by interfacing with a catch feature 48 until the cable link 14 is actuated and disengages the pawl 42 from the cam 40 by contacting a pawl override contact surface 50, thereby allowing the cam 40 to return to an unlocked state via the cam return spring 46. The pawl 42 naturally is returned in a counterclockwise direction (in the illustrated perspective). The gear 44 rotates clockwise (in the illustrated perspective) and drives the cam 40 to a locked state, and then continues its rotation until it hard stops on the cam 40.

[0015] FIGS. 12-26 illustrate the drive lock mechanism 10 in a plurality of positions, conditions and states. FIG. 12 illustrates the position of the pawl 42 when it is moved to a release position by the cable link 14 to achieve full travel. The pawl 42 becomes disengaged from the cam catch feature 48 in this position. FIG. 13 shows the cam 40 returning via return spring 46 and driving the release clutch 30 to ride on the pawl release link 12. FIG. 14 displays the cable link 14 returning to its home position. The pawl 42 is now riding on the cam catch feature 48 and the cam 40 is driving the release clutch 30 counterclockwise, and is now free to couple the release clutch 30 between the cable link 14 and the pawl release link 12. FIG. 15 shows the system back in an unlocked state. The cam 40 is driving the release clutch 30 and coupling it between the cable link 14 and the pawl release link 12. The pawl 42 is resting on the cam 40 and the latch is now able to be manually released.

[0016] FIGS. 16-22 illustrate the cam 40, the gear 44, a worm gear 60 and a motor 62. These components provide electric relocking functionality. FIG. 17 shows the system in an unlocked state. The cam 40 is naturally being returned and a gear cam drive feature 64 is free to rotate clockwise. FIG. 18 shows the gear 44 rotating clockwise (in the illustrated perspective). It is being driven by the motor 62 and the worm gear 60. The gear 44 is making it initial contact with the cam 40 via the gear cam drive feature 64, and is beginning to drive it clockwise. FIG. 19 illustrates the travel of the gear 44, the cam 40 and the release clutch 30, as the gear 44 drives the cam 40 from an unlocked state to a locked state. FIG. 20 shows the action of the pawl 42 as the cam 40 moves to a locked state. The pawl 42 moves into a bite condition with the cam catch feature 48 and holds the system in a locked state. FIG. 21 shows the remaining travel of the gear 44 after it has driven the cam 40 to a locked state. The gear 44 continues its clockwise rotation until it hard stops on a cam stop surface 68. FIG. 22 shows the system in a locked state after an electric relock.

[0017] Referring now to FIGS. 23-26, a switch 70 is illustrated at various positions. FIG. 23 shows switch 70 displayed position when the cable link 14 is in its initial position. The switch 70 is currently OFF and no current is driving through the switch 70. FIG. 24 illustrates the switch 70 position when the cable link 14 is fully actuated. The switch 70 is now ON and is sending an electric current to a controller. FIG. 25 shows the switch 70 in comparison to the remaining components of the assembly when the cable link 14 is at full travel. FIG. 26 illustrates the activation point of the switch 70. When the cable link 14 is moving towards full travel, the switch 70 will turn ON. During the return of the cable link 14 to its home position, the switch 70 will be deactivated at approximately mid-travel of the cable link 14. At this point in time, the controller will see that the switch 70 has turned OFF and will energize the motor 62, initiating an electric relock. By placing this point at mid-travel, the pawl 42 is no longer being held open by the cable link 14, meaning that it is able to hold the cam 40 in a locked state again. The release clutch 30 has also not fully been returned to a home position, so it has not become coupled between the cable link 14 and the pawl release link 12. Therefore, the system is able to electrically reset back to a locked state, without fully becoming unlocked.

[0018] While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.