Closure latch assembly with release cable arrangement having an anti-chatter mechanism

Abstract

The present disclosure relates to a closure latch assembly and system for a vehicle closure panel, equipped with a latching mechanism having a latched position and an unlatched position, and a power release mechanism movable between an original position, a release position, and a double pull and / or child lock position, wherein a motor is operable to move the power release mechanism from the original position to the release position and from the original position to the double pull and / or child lock position, and wherein an emergency back-up mechanism in mechanical communication with the latching mechanism can be mechanically actuated from a non-deployed position to a deployed position to move a pawl from a ratchet holding position to a ratchet release position regardless of the position of the power release mechanism, wherein the emergency back-up mechanism is prevented from making a rattle noise when in the non-deployed position.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 298,420, filed January 11, 2022, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] This disclosure generally relates to closing latches for vehicle passenger doors. More specifically, this disclosure relates to closing latches equipped with a power release mechanism and a mechanically actuated emergency release mechanism. Background Technology

[0004] This section provides background information related to closing latches and is not necessarily prior art for closing latches disclosed herein.

[0005] Some vehicles are equipped with passive entry systems that allow a vehicle user with a key card to open the door simply by pulling the door handle without inserting a key into the keyhole. The key card is typically equipped with electronics that communicate with the vehicle's onboard control system to authenticate the user. When the user pulls the outer door handle to indicate his / her intention to enter the vehicle, an electric actuator associated with a closing latch mounted on the door is actuated to release the latch mechanism, thereby unlatching the door and allowing it to subsequently move to the open position. The outer door handle may also be equipped with a switch that triggers the electric actuator. The latch mechanism can also be mechanically released from the inside of the vehicle, as the inner door handle is connected to an inner release mechanism associated with the closing latch. However, in some jurisdictions, regulations govern the degree of connection provided by the inner release mechanism between the inner door handle and the latch mechanism (particularly for rear doors where a child may be a passenger).

[0006] In addition to the double-pull inside release function, many modern latches offer a variety of power-operated features, including power release, power locking, and power child lock. While commercially available latches satisfactorily meet operational and regulatory requirements, there is still a need for improved technology to provide latches with reduced complexity and encapsulation, while also providing the ability to open the rear door via an alternative opening mechanism in the event of a power interruption of power to the power-operated actuator. The alternative opening mechanism needs to be economical in terms of manufacture and assembly; compliant with government regulations; and allow the intended operation of the latch assembly during normal use without negatively impacting the desired performance properties of the latch assembly—including smooth, noiseless operation. Therefore, continuous efforts are being made to address at least the aforementioned issues. Summary of the Invention

[0007] This section provides a general summary of the disclosure and is not intended to be exhaustive or to be limited in scope or in aspects, features, and objectives to those described.

[0008] One aspect of the present disclosure is to provide a closure latch system for a motor vehicle closure panel, such as a passenger door, having a powered release actuator movable between an original position where the latch mechanism is in a latched position, a release position where the latch mechanism is in an unlatched position, and a child lock position where the latch mechanism is prevented from moving from the latched position to the unlatched position, the closure latch system further comprising an emergency release system configured to be manually actuated to allow the latch mechanism to move to the unlatched position regardless of the position of the powered release actuator to allow the passenger door to be opened.

[0009] Another aspect of the present disclosure is to provide a powered closure latch system for a vehicle closure panel, such as a passenger door, having a powered release actuator movable to a child lock position where the latch mechanism is prevented from moving from the latched position to the unlatched position to prevent the passenger door from being opened from an inside release mechanism, the closure latch system further comprising an emergency release system configured to be manually actuated to allow the latch mechanism to move to the unlatched position when the latch mechanism is in the child lock position to allow the passenger door to be opened.

[0010] Another aspect of the present disclosure is to conceal the emergency release system to prevent accidental access to avoid the latch mechanism from accidentally moving from the latched position to the unlatched position when the latch mechanism is in the child lock position.

[0011] Another aspect of the present disclosure is to provide an emergency release system that is noiseless during use of the motor vehicle.

[0012] Another aspect of the present disclosure is to provide an emergency release system that is economical in terms of manufacturing and assembly.

[0013] Another aspect of the present disclosure is to provide an emergency release system that allows the latch assembly to remain in compliance with government regulations.

[0014] According to these and other aspects, a closure latch assembly for a door of a motor vehicle includes a latch mechanism including a ratchet and a pawl, the ratchet movable between a striker capture position and a striker release position, the pawl movable between a ratchet hold position, at which the pawl holds the ratchet in its striker capture position, and a ratchet release position, at which the pawl allows the ratchet to move to its striker release position. The closure latch system further includes a power release mechanism movable by an actuator between an original position, at which the pawl can be moved from the ratchet hold position to the ratchet release position with a single actuation of the power release mechanism, and at least one of a double pull lock position and a child lock position, at which the pawl cannot be moved from the ratchet hold position to the ratchet release position with a single actuation of the power release mechanism or a single actuation of an inboard release member. The closure latch system further includes an emergency back-up mechanism configured to communicate in mechanical communication with the latch mechanism, wherein a mechanical actuation of the emergency back-up mechanism from a non-deployed position to a deployed position moves the pawl from the ratchet hold position to the ratchet release position regardless of the position of the power release mechanism, wherein the emergency back-up mechanism has a pre-loaded bias exerted on the emergency back-up mechanism to prevent a rattle noise from being emitted when in the non-deployed position and when the motor vehicle is moving.

[0015] According to another aspect, the emergency back-up mechanism has a cable assembly mechanically coupled to a release lever of the latch mechanism, wherein the pre-loaded bias is exerted on the cable assembly.

[0016] According to another aspect, the cable assembly can include an outer tubular cable conduit and a central cable extending through the outer tubular cable conduit along a cable axis, wherein the bias is exerted on the central cable.

[0017] According to another aspect, the bias can be exerted on the central cable as a tension.

[0018] According to another aspect, the bias can be exerted on the central cable as a constant tension.

[0019] According to another aspect, the bias can be exerted on the central cable by a spring member.

[0020] According to another aspect, the spring member can be configured to exert the bias directly on the release lever, whereby the release lever can be configured to exert the bias on the central cable.

[0021] According to another aspect, the stop member can be fixed to the central cable, wherein a bias exerted on the central cable pulls the stop member into engagement with a stop surface fixed against movement along the cable axis to maintain tension on the central cable when the emergency back-up mechanism is in the non-deployed position, thereby preventing the generation of a rattle and noise by the emergency back-up mechanism when the motor vehicle is driven.

[0022] According to another aspect, a pulling member can be provided at the free end of the central cable, wherein the stop member is located between the pulling member and the stop surface, wherein the pulling member is configured to pull substantially along the cable axis to move the stop member away from the stop surface and to move the release lever against the bias exerted by the spring member, thereby moving the pawl from the ratchet retaining position to the ratchet release position when the emergency back-up mechanism is in the deployed position, irrespective of the state of the power release mechanism.

[0023] According to another aspect, the stop surface can be fixed to the outer tubular cable conduit.

[0024] According to another aspect, the stop surface can be provided with a circumferentially extending groove configured for fixedly receiving an edge of a panel of the vehicle door in the groove, thereby preventing undesired relative movement of the stop surface along the cable axis.

[0025] According to another aspect, the outer tubular cable conduit extends between opposite first and second end portions, wherein the stop surface can be fixed to the first end portion, thereby preventing undesired relative movement of the stop surface and the outer tubular cable conduit along the cable axis.

[0026] According to another aspect, the second end portion of the outer tubular cable conduit can be fixed to the housing of the closure latch assembly, thereby preventing undesired relative movement of the outer tubular cable conduit along the cable axis.

[0027] According to another aspect of the disclosure, a method of constructing a closure latch system for a vehicle door is provided. The method includes the step of constructing a latch mechanism including a ratchet movable between a striker capture position and a striker release position and a pawl movable between a ratchet retaining position, at which the pawl retains the ratchet in the striker capture position, and a ratchet release position, at which the pawl allows the ratchet to move to the striker release position. Further, the method includes the steps of constructing a power release mechanism having an original position, a locked position, and a child lock position and constructing an inboard door handle in operable communication with the power release mechanism, wherein the inboard door handle has a rest position, a first deployment position, and a second deployment position. The pawl is moved from the ratchet retaining position to the ratchet release position under power of the power release mechanism in response to a single actuation of the inboard door handle from the rest position to the first deployment position when the power release mechanism is in the original position, and the pawl does not move from the ratchet retaining position to the ratchet release position under power of the power release mechanism in response to a single actuation of the inboard door handle from the rest position to the first deployment position when the power release mechanism is in the locked position. Another step includes constructing an emergency back-up mechanism in mechanical communication with the latch mechanism, wherein the emergency back-up mechanism is actuatable to move the pawl from the ratchet retaining position to the ratchet release position without assistance from the power release mechanism when the power release mechanism is in either of the original position and the locked position, and a pre-loaded bias is applied on the emergency back-up mechanism to prevent a rattle noise from being emitted when in a non-deployed position and while the motor vehicle is moving.

[0028] According to another aspect of the method, the steps include providing an emergency back-up mechanism having a cable assembly mechanically coupled to a release lever of the latch mechanism, wherein the cable assembly includes an outer tubular cable conduit and a central cable extending through the outer tubular cable conduit along a cable axis, and constructing a bias applied on the central cable.

[0029] According to another aspect, the method can include constructing a spring member to apply the bias directly on the release lever and constructing the release lever to apply the bias on the central cable.

[0030] According to another aspect, the method can include securing a stop member to the central cable such that the bias applied on the central cable pulls the stop member into engagement with a stop surface secured to prevent movement along the cable axis to maintain tension on the central cable when the emergency back-up mechanism is in a non-deployed position.

[0031] According to another aspect, the method can include providing a pull member at the free end of the central cable, wherein the stop member is located between the pull member and the stop surface; and configuring the pull member to be pulled generally along the cable axis to move the stop member away from the stop surface to move the release lever against the bias applied by the spring member to move the pawl from the ratchet retaining position to the ratchet release position when the emergency back-up mechanism is in the deployed position regardless of the state of the power release mechanism.

[0032] According to another aspect, the method can include securing the stop surface to the outer tubular cable conduit.

[0033] According to another aspect, the method can include securing the stop surface to a first end of the outer tubular cable conduit and securing a second end of the outer tubular cable conduit to the housing of the closure latch assembly to prevent relative movement of the outer tubular cable conduit along the cable axis.

[0034] According to another aspect, a method of configuring a closure latch for a vehicle door includes configuring a latch mechanism including a ratchet movable between a striker capture position and a striker release position and a pawl movable between a ratchet retaining position and a ratchet release position, at the ratchet retaining position the pawl retains the ratchet in the striker capture position, at the ratchet release position the pawl allows the ratchet to move to the striker release position; configuring a release lever in mechanical communication with the latch mechanism, wherein the release lever is actuatable to move the pawl from the ratchet retaining position to the ratchet release position in response to actuation of a release member; and applying a pre-loaded bias on the release lever to apply tension to the release member.

[0035] According to another aspect, a closure latch assembly for a vehicle door is provided, the closure latch assembly including a latch mechanism including a ratchet movable between a striker capture position and a striker release position and a pawl movable between a ratchet retaining position and a ratchet release position, at the ratchet retaining position the pawl retains the ratchet in its striker capture position, at the ratchet release position the pawl allows the ratchet to move to its striker release position; and a release lever operably coupled with the pawl, wherein actuation of the release lever from a non-deployed position to a deployed position moves the pawl from the ratchet retaining position to the ratchet release position, a release member is operably coupled to the release lever, the release member for actuating the release lever such that relative movement between the release member and the release lever is inhibited when the release member is coupled to the release lever to prevent noise emission during vibration of the closure latch assembly.

[0036] Other applicable fields will become apparent from the description provided herein. As indicated, the description in the summary and any specific examples are intended only for purposes of illustration and are not intended to limit the scope of the disclosure. Attached Figure Description

[0037] The accompanying drawings described herein have been provided to illustrate selected embodiments and their specific features, and are not intended to limit the scope of this disclosure. This disclosure will now be described by way of example only with reference to the accompanying drawings, in which:

[0038] Figure 1 It is an isometric view of a motor vehicle including a door equipped with a closing latch assembly constructed according to various aspects of this disclosure;

[0039] Figure 2 It is constructed according to one aspect of this disclosure for use in Figure 1 An isometric view of a closing latch assembly used in a car door, shown as arranged to receive a striker therein;

[0040] Figure 3A It shows Figure 2 The rear isometric view of the latching mechanism, release mechanism, and some internal components of the closed latch assembly, shown in latching mode;

[0041] Figure 3B yes Figure 3A Isometric front view of the release mechanism and latching mechanism;

[0042] Figure 4 This is an end view of the closed latch assembly, showing the child lock latch moving from the deactivated position (dashed line) to the activated position (solid line);

[0043] Figure 5A This is an exploded view illustrating the chain of action between a child lock feature operatively connected to the inside door handle and a closing latch assembly, wherein the child lock feature is shown in the child lock closed position;

[0044] Figure 5B This is a side view showing the child lock features in the child lock open position;

[0045] Figure 6 This is a flowchart illustrating a closed latching system according to one aspect of the present disclosure;

[0046] Figure 7 This is a flowchart illustrating a closed latching system according to another aspect of the present disclosure;

[0047] Figures 8 to 15 The illustrations depict various aspects and operation of a closing latch assembly and a closing latch system having the closing latch assembly according to various aspects of this disclosure;

[0048] Figures 16 to 26FIGS. 1-3 illustrate aspects of a closure latch assembly and closure latch system having the closure latch assembly in accordance with aspects of the present disclosure;

[0049] Figure 27 、 Figure 27A and Figure 28 FIG. 12 illustrates an emergency override mechanism of a closure latch system in accordance with another aspect of the present disclosure;

[0050] Figure 29 is a flowchart illustrating a closure latch system in accordance with another aspect of the present disclosure;

[0051] Figure 30 is a flowchart illustrating a closure latch system in accordance with yet another aspect of the present disclosure;

[0052] Figure 31 is an isometric view of a motor vehicle including a vehicle door equipped with a closure latch assembly configured in accordance with another aspect of the present disclosure;

[0053] Figure 32 is Figure 31 a schematic view of the bracketed area 32 of

[0054] Figure 33 is a view similar to Figure 32 illustrating a sequence of normal release of the closure latch assembly via selective movement of the inboard handle of the inboard actuation assembly;

[0055] Figure 34 is a view similar to Figure 32 illustrating a sequence of emergency release of the closure latch assembly via selective movement of the emergency release member of the inboard actuation assembly;

[0056] Figure 35 : is a schematic view of the closure latch system during a normal release state via actuation of the inboard release mechanism while in a locked closed position corresponding to Figures 19 to 21 and Figure 33 is a schematic view of the closure latch system during a normal release state via actuation of the inboard release mechanism while in a child lock closed position corresponding to

[0057] Figure 36 : is a view similar to Figure 35 illustrating a sequence of normal release of the closure latch assembly via selective movement of the inboard handle of the inboard actuation assembly; Figures 23 to 24is a schematic view of the closure latch system showing the controller in operable communication with the inboard release mechanism; and

[0058] Figure 37 is a view similar to Figure 35 is a view similar to

[0059] Figure 38 is a flowchart illustrating a method of configuring a closure latch system for a vehicle door according to another aspect of the present disclosure.

[0060] Figures 39 to 41B illustrates an emergency back-up mechanism of a closure latch system according to yet another aspect of the present disclosure;

[0061] Figure 42A and Figure 42B illustrates an alternative embodiment of a portion of an emergency back-up mechanism of a closure latch system according to yet another aspect of the present disclosure; Figures 39 to 41B

[0062] Figure 43A illustrates a cable of an emergency back-up mechanism in an undesired state of being untensioned;

[0063] Figure 43B illustrates a cable of an emergency back-up mechanism in a state of being tensioned according to an aspect of the present disclosure; and

[0064] Figure 44 is a flowchart illustrating a method of configuring a closure latch system for a vehicle door according to another aspect of the present disclosure. DETAILED DESCRIPTION

[0065] Example embodiments of a closure latch for use in a motor vehicle door closure system are provided so that the present disclosure will be thorough, and to fully convey the scope of the application to those skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. Those skilled in the art will recognize that the example embodiments can be practiced without one or more of the specific details, or with other methods, components, materials, etc. In some instances, well-known structures, devices, and techniques have not been described in detail or have been omitted so as to not obscure the relevant details of the present disclosure.

[0066] ​The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a," "an," and "the" can be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," "including" and "having," are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order

[0067] When an element or layer is referred to as being "on," "engaged to," "connected to," or "coupled to" another element or layer, it can be directly on, engaged, connected, or coupled to the other element or layer, or one or more intervening elements or layers can be present. In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to," or "directly coupled to" another element or layer, there are no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0068] Although the terms first, second, third, etc. can be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms can be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as "first," "second," and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, a first component, a first region, a first layer or a first section discussed below could be termed a second element, a second component, a second region, a second layer or a second section without departing from the teachings of example embodiments.

[0069] For purposes of the description hereinafter, spatial relative terms, such as "inner," "outer," "lower," "bottom," "bottom," "top," "upper," "top," "bottom," etc., can be used to describe an element's relationship to another element(s) as illustrated in the figures. Spatial and directional relative terms can be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the example term "below" can encompass both an orientation of above and below. The device can be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0070] Referring initially to Figure 1 , a closure latch assembly, also referred to as a closure latch or latch assembly 10, for a closure panel, such as a swing door, shown by way of example and not limitation as a rear door 12, of a motor vehicle 14 is shown positioned along a closing face portion 16 of the door 12 and is configured to releasably engage and capture a striker 18 secured to a vehicle body 22 for extension within a door opening 20 formed in the vehicle body 22 in response to the door 12 moving from an open position to a closed position. The door 12 is shown to include an outboard door handle 24 and an inboard door handle 26, both of which are operatively (i.e., electrically and / or mechanically) connected to the closure latch assembly 10. Although not shown, it will be appreciated that a similar closure latch assembly is provided in association with a front door 13 of the vehicle 14, which is shown to include its own outboard door handle 25.

[0071] Referring now to Figures 2 to 3B , a non-limiting example embodiment of the closure latch assembly 10 and its internal components is shown to generally include a latch mechanism 31 and a powered latch release mechanism (hereinafter simply referred to as a latch release mechanism 33. Figure 3A and Figure 3B ) By way of example and not limitation, the latch mechanism 31 is shown to be a dual pawl-dual ratchet configuration having a primary ratchet, also referred to as a main ratchet 32, a primary pawl, also referred to as a main pawl 36, a secondary ratchet, also referred to as an auxiliary ratchet 38, and a secondary pawl, also referred to as an auxiliary pawl 40. The main ratchet 32 is pivotally mounted to a plate section 28 of the latch housing 29 and has a fishmouth slot 30 formed in the latch housing 29. Figure 2) aligned ratchet slot 34. The primary ratchet 32 is movable between a primary closed position or "plunger capture" position, at which the plunger 18 is held within the fishmouth slot 30 by being captured in the ratchet slot 34, and an open position or "plunger release" position, at which the plunger 18 is freely released from the ratchet slot 34 and the fishmouth slot 30. The primary ratchet 32 is biased toward the plunger release position of the primary ratchet 32 by a primary ratchet biasing member, such as a primary ratchet spring 32' (shown in phantom) Figure 3A and Figure 3B ) by way of example and not limitation, is shown as being pivotably supported by a secondary ratchet 38 for movement between a fixed primary ratchet lock position, also referred to as a "closed" position, at which the primary pawl 36 positions and holds the primary ratchet 32 in the plunger capture position of the primary ratchet 32, and an unfixed primary ratchet release position, also referred to as an "open" position, at which the primary pawl 36 is positioned to allow the primary ratchet 32 to move to the plunger release position of the primary ratchet 32, such as under biasing provided by the primary ratchet spring 32' on the primary ratchet 32. A primary pawl biasing member, such as a primary pawl spring 36', is operable to normally bias the primary pawl 36 toward the open position of the primary pawl 36. The secondary ratchet 38 is pivotably mounted to the plate segment 28 of the latch housing 29 for movement between a first position or "engaged" position, at which the secondary ratchet 38 holds the primary pawl 36 in the closed position of the primary pawl 36, and a second position or "disengaged" position, at which the secondary ratchet 38 allows the primary pawl 36 to bias toward the open position of the primary pawl 36. A secondary ratchet biasing member, such as a spring member (not shown), is provided to normally bias the secondary ratchet 38 toward its engaged position. Finally, a secondary pawl 40 is pivotably mounted to the plate segment 28 for pivoting about a pivot axis PA for movement between an auxiliary ratchet lock position, also referred to as a first position or "closed" position, at which the secondary pawl 40 holds the secondary ratchet 38 in its engaged position, and an auxiliary ratchet release position, also referred to as a second position or "open" position, at which the secondary pawl 40 is positioned to allow the secondary ratchet 38 to move to its disengaged position. A secondary pawl biasing member, such as a secondary pawl spring (not shown), is provided to normally bias the secondary pawl 40 toward its closed position in engagement with the auxiliary ratchet 38 or to a blocking position against the auxiliary ratchet 38.

[0072] The latch release mechanism 33 is in Figure 3A and Figure 3BThe latch assembly 10 is best shown as including a power actuator and a power release gear 43, the power actuator shown as a single electric motor 41 shown as including a motor shaft having a worm gear WG fixed thereto, the power release gear 43 driven by the worm gear WG of the electric motor 41 for driving an actuator release lever, also referred to as an actuator lever 58, for driving a latch release lever, also referred to as a release lever and shown by way of example and without limitation as an auxiliary pawl release lever 60, via engagement of a cam member 44 fixed to the power release gear 43 with a first end region 46 of the actuator lever 58, which in turn drives the auxiliary pawl release lever 60 for moving the secondary pawl 40 from its closed position to its open position to provide the power release function of the latch mechanism 31.

[0073] Rotation of the power release gear 43 in a first direction or "release" direction 50 Figure 10 ) results in the latch mechanism 31 being moved to its ratchet release position via the primary pawl 36 and the primary ratchet 32 being allowed to move to its striker release position and release, and rotation in an opposite direction or "reset" direction 52 Figure 11 ) results in the latch mechanism 31 being reset. The actuator release lever 58 is directly or operably engaged (linked) with the auxiliary pawl release lever 60 when the auxiliary pawl release lever 60 is in a rest position and can be moved by the actuator 41 to move the auxiliary pawl release lever 60 to an engaged position. As is known, actuation of a key fob or inside handle switch 53 in operable communication with door handles 24, 25 on the doors 12, 13 can provide a signal to an electronic control unit (ECU) associated with the closure latch assembly 10, such as a controller shown as being in the form of a body control module (BCM) 54 and / or a latch controller 55 in Figure 6 provides a signal to the electronic control unit (ECU) indicating a request to release the latch mechanism 31. The ECU and / or latch controller 54, 55 thus controls operation of the motor 41 to rotate the power release gear 43. Any suitable primary power source 56a and backup power source 56b can be provided for operable communication with the ECU and / or latch controller 54, 55. By way of example and without limitation, Figure 6 A child lock status switch 47 and a power release motor home position switch 45 are also shown in FIG. 1 as being configured for operable communication with the latch controller 55 and a vehicle status sensor 61 is shown as being configured for operable communication with the ECU 54. In Figure 7 another embodiment shown in FIG. 2, the inside handle switch 53 and the child lock status switch 47 are shown as being configured for operable communication with the latch controller 55, in addition to which, Figure 7 the embodiment of FIG. 2 is similar to that of FIG. 1Figure 6 The illustrated embodiments are identical.

[0074] The auxiliary pawl release lever 60 is coupled with the auxiliary pawl 40, and as illustratively shown in Figure 3A and Figure 3B The auxiliary pawl release lever 60 is biased into direct engagement with the auxiliary pawl 40 via a counter biasing member acting on the auxiliary pawl 40 (as indicated by arrow H), and the auxiliary pawl release lever 60 is coupled with the auxiliary ratchet 38, and the auxiliary pawl release lever 60 is shown as being biased into direct engagement with the auxiliary ratchet 38 via a counter biasing member acting on the auxiliary pawl release lever 60 (as indicated by arrow "I"). In addition to the spring member I, the auxiliary pawl release lever 60 is further biased by the engagement of the actuator release lever 58 under the bias of the actuator release lever biasing spring 59 as indicated by arrow "J" shown in Figure 3A Figure 3A The auxiliary pawl release lever 60 can be moved between a rest position where the auxiliary pawl 40 is in its closed position and the primary pawl 36 is in its closed position, and a fully engaged position where the auxiliary pawl 40 is moved to its open position and the primary pawl 36 is moved to its open position. Figure 3A

[0075] The auxiliary ratchet 38 is operatively coupled to the primary pawl 36, where the primary pawl 36 is shown as being retained for pivotal movement in a cylindrical pocket 62 of the auxiliary ratchet 38. As noted above, the auxiliary ratchet 38 can be moved between its engaged position where the auxiliary ratchet 38 retains the primary pawl 36 in its closed position, and its disengaged position where the auxiliary ratchet 38 moves the primary pawl 36 to its open position. Under the driving influence of the auxiliary pawl release lever 60 and the actuator release lever 58, the auxiliary ratchet 38 is moved to its disengaged position against the bias of the spring biasing member, and the auxiliary pawl 40 is forced to move to its open position against the spring biasing member due to the driving influence of the actuator release lever 58 acting on the auxiliary pawl release lever 60 against the spring biasing member J as the power release gear 43 is rotated in the release direction 50 to the release position.

[0076] The single motor 41 associated with the release chain 64 and the dual pull mechanism 66 having a single pull state and a dual pull state operates to perform a selected one of the following: the power release latch assembly 10, placing the latch mechanism 31 of the latch assembly 10 in the single pull state, and placing the latch mechanism 31 of the latch assembly 10 in the dual pull state. The operation and logic flow of the closing latch assembly 10 is shown in Figures 8 to 15 and is discussed in greater detail hereinafter.

[0077] ​​The release chain 64 includes a latch mechanism 31 that includes an actuator release lever 58 and an auxiliary pawl release lever 60. It should be appreciated that the latch mechanism 31 is illustrated and described as having a dual pawl / dual ratchet mechanism; however, a single pawl / single ratchet mechanism is contemplated herein. The single motor 41 is capable of actuation to move the dual pull mechanism 66 into one of its single pull and dual pull states, wherein activation of the single motor 41 operates to perform a selected one of: power release the latch assembly 10 via the release chain 64, place the dual pull mechanism 66 of the latch assembly 10 in the single pull state, and place the dual pull mechanism 66 of the latch assembly 10 in the dual pull state.

[0078] Figure 8 The inside release mechanism 68 is a non-limiting embodiment of an inside release mechanism 68 operatively associated with the power latch release mechanism 33 for use with the closure latch assembly 10. The inside release mechanism 68 is shown to include an inside release lever 70 that is pivotably movable between a first or "home" position (shown) and a second or "actuated" position Figure 10 and Figure 11 ), an inside release lever spring 72 that is operable to normally bias the inside release lever 70 to its home position, an auxiliary release lever 74 Figure 12 and a link 76. The inside release lever 70 is mechanically connected to the inside door handle 26 via a suitable coupling mechanism 78 Figure 12 . The inside release lever 70 is supported for pivotal movement between a first or "home" position and a second or "actuator lever release" position relative to a post (not shown). The auxiliary release lever 74 is biased toward its home position via an actuator lever spring acting thereon. The auxiliary release lever 74 is formed to include an actuation lug 80 that is engageable with a release lug 82 formed on the actuator release lever 58, as well as a slotted portion defining a bypass cavity (hidden) and a drive lug 84. The link 76 includes an elongated slot 86 and a guide post 88 that is held for sliding movement within a drive slot 90 formed in the inside release lever 70. When the link 76 is in a first or "disengaged / retracted" position, the guide post 88 on the link 76 is aligned with the bypass cavity (not shown) in the auxiliary release lever 74. Conversely, when the link 76 is in a second or "engaged / extended" position, the guide post 88 is aligned with the drive lug 84 on the auxiliary release lever 74. As will be described in detail, movement of the inside release lever 70 between its home and actuated positions cooperatively controls selective pivotal movement of the auxiliary release lever 74 between its home and actuator lever release positions in coordination with movement of the link 76 between its disengaged and engaged positions.

[0079] The double-pull actuation mechanism 92 is arranged to be operatively associated with the inner release mechanism 68 for use with the closing latch assembly 10. The double-pull actuation mechanism 92 is shown generally comprising a double-pull rod 94 and a double-pull rod spring 95. The double-pull rod 94 is pivotally movable about a pivoting column 96 between a first position or "double-pull-open" position and a second position or "double-pull-closed" position. The double-pull rod spring 95 acts on the double-pull rod 94 and causes the double-pull rod 94 to be normally biased toward its double-pull-closed position. The double-pull rod 94 includes a first leg-like section 98 and a second leg-like section 99, wherein the second leg-like section 99 has a profiled drive groove 100. As observed, the second leg-like section 99 is positioned between the link 76 and the inner release rod 70 such that a guide column 88 on the link 76 passes through the drive groove 100 in the double-pull rod 94 and the drive groove 90 in the inner release rod 70.

[0080] The power release mechanism 33 and its power release gear 43 can be in the original position by a single actuator 41. Figure 9 ) and also known as the double pull position or double locking position ( Figure 13 The power release gear 43 can move between the double-pull locking positions. In the original position, the power release gear 43 can be sensed by an original position sensor / switch, also known as the first sensor 45, such that when the power release gear 43 is in its original position, by way of example rather than limitation, the switch can be triggered by the cam member 44. In the original position, the pawl 36 can move from the ratchet holding position to the ratchet release position with a single actuation of the power release mechanism 33 or with a single actuation of the inner handle 26. In the double-pull locking position, the pawl 36 cannot move from the ratchet holding position to the ratchet release position with a single actuation of the power release mechanism 33 or with a single actuation of the inner handle 26. When the power release mechanism 33 is in the double-pull locked position, the pawl 36 can only move from the ratchet holding position to the ratchet release position when the double actuation of the power release mechanism 33 is performed. Specifically, when the double actuation of the power release mechanism 33 is performed, or when the double actuation of the inner handle 26 is performed, the power release mechanism 33 moves directly from the double-pull locked position to the release position. Otherwise, the pawl 36 will remain in its ratchet holding position.

[0081] According to another aspect of this disclosure, in Figures 16 to 30 The diagram shows a closed latch assembly 110 and a closed latch system 110' for the closed latch assembly 110, wherein the same reference numerals offset by a factor of 100 in some cases are used to identify similar features.

[0082] By way of example rather than limitation, the closed latch system 110' and its closed latch assembly 110 are described in... Figure 16The rear passenger door 12 is shown configured for a vehicle 14. The closure latch system 110’ includes a power-actuated child lock feature to selectively disable the inboard rear door handle 26 from moving the closure latch assembly 110 from the latched state to the unlatched state when in the child lock open position. The closure latch assembly 110 is the same or substantially the same as discussed above for the closure latch assembly 10, and therefore, it is not necessary to repeat the discussion of the closure latch assembly 110 as one of ordinary skill in the art will readily understand the workings of the closure latch assembly 110 without unnecessary repetition. The power-actuated child lock feature is selectively movable from the child lock closed position to the child lock open position at which the rear door handle 26 is operable to move the closure latch assembly 110 from the latched state to the unlatched state. As shown in Figure 17 By way of example and not limitation, the child lock button or switch S is shown as being accessible on the inner front door panel immediately adjacent to the front row driver seat, as shown in Figure 29 The child lock switch S is configured to be in electrical communication with a controller, such as a body control module BCM 154, as shown in Figure 30 The child lock switch S can be configured to be in direct electrical communication with the latch controller 155, if desired, as shown in

[0083] The various positions of the power release gear 143 associated with the power actuator 141 of the power release mechanism 133 are shown in Figures 19 to 26 In Figures 19 to 22 the child lock closed position, the power release gear 143 can be sensed via a home position sensor / switch, also referred to as a first sensor 145, such that by way of example and not limitation, the switch can be triggered by the cam member 144 when the power release gear 143 is in its home position. In this position, the rear door handle 26 is operable to move the closure latch assembly 110 from the latched state to the unlatched state. Conversely, in Figure 23 and Figure 24In the child lock open position, the power actuated child lock feature can be sensed by the child lock position sensor / switch, also referred to as second sensor 147, such that by way of example and not limitation, the switch can be triggered by the cam member 144 when the power release gear 143 is in its child lock position. In this position, the rear door handle 26 cannot be operated to move the closure latch assembly 110 from the latched state to the unlatched state. Accordingly, the rear door handle 26 is temporarily disconnected from electrical communication with the power actuator 141, and thus, the rear door handle 26 cannot command the closure latch assembly 110 to move from the latched state to the unlatched state. As shown in Figure 25 enabling the child lock switch S, such as by the driver seated in the driver's seat, can drive the power actuator 141 to move the power actuated child lock feature from the child lock open position to the child lock closed position, where the rear door handle 26 can again be operated to move the closure latch assembly 110 from the latched state to the unlatched state. Accordingly, the rear door handle 26 is reconnected for electrical communication with the power actuator 141, and thus, the rear door handle 26 can command the closure latch assembly 110 to move from the latched state to the unlatched state.

[0084] In Figure 27 and Figure 27A the emergency back-up mechanism (EBM) is shown to provide the ability to move the closure latch assembly 110 from the latched state to the unlatched state mechanically without the aid of the power actuator 141. The emergency back-up mechanism is an example of a latch release mechanism, and it is recognized that other types of release mechanisms can be employed to actuate the release lever RL, such as a hidden handle assembly, as well as an outboard handle assembly, an inboard handle assembly, a remote power actuator, a lever system, but as non-limiting examples only. Accordingly, in the event that the power to the power actuator 141 is inadvertently interrupted, by way of example and not limitation, a passenger within the motor vehicle 14 can access the emergency back-up mechanism EBM, such as via the access opening 102 covered by the emergency access panel or cover L, to manually move the closure latch assembly 110 from the latched state to the unlatched state. The emergency back-up mechanism EBM can be provided by a handle, lever, pull-tab, pull-ring, etc. attached to a cable, such as a Bowden cable, which is mechanically coupled to the release lever RL Figure 28 ), which can be moved to move the pawl to the ratchet release position to move the latch assembly 110 from the latched state to the unlatched state. Accordingly, although the closure latch assembly 110 is intended to be actuatable only by the inboard handle 26 via power actuation in "normal use", in the event of a power interruption, the closure latch assembly 110 can be unlatched via manual actuation of the mechanical linkage. As shown in Figure 16As shown schematically, the outboard door handle 24 can be configured for manual actuation via a Bowden cable.

[0085] In Figure 31 , by way of example and not limitation, the closure latch system 210' and its closure latch assembly 210 are shown as configured for use on a rear passenger door 12 of the vehicle 14. The closure latch system 210' includes a child lock feature to selectively disable the inboard rear door release member, such as the rear door handle 226, from moving the closure latch assembly 210 from the latched state to the unlatched state when in a child lock open position. The closure latch system 210' and its closure latch assembly 210 are the same or substantially the same as discussed above with respect to the closure latch assembly 10, 110 and the closure latch system 110', and therefore, it is not necessary to repeat the discussion as one of ordinary skill in the art would readily understand the operation of the closure latch system 210' and the closure latch assembly 210 without repetition. The power actuated child lock feature can be selectively moved from a child lock closed position Figure 33 , Figure 35 and Figure 37 to a child lock open position Figure 36 , at which the rear door handle 226 is operable to move the closure latch assembly 210 from the latched state to the unlatched state, at which the rear door handle 226 is not operable to move the closure latch assembly 210 from the latched state to the unlatched state. As shown in Figure 17 , by way of example and not limitation, a child lock button or switch S shown as being accessible on an inboard front door panel immediately adjacent to a front row driver seat is operable to move the power actuated child lock feature of the closure latch system 210' and its closure latch assembly 210 between the child lock closed position and the child lock open position. As shown in Figure 29 , the child lock switch S is configured in electrical communication with a controller, such as a body control module BCM 154, where the BCM 154 can be configured in electrical communication with a latch controller 155, which can be configured in electrical communication with a power actuator 141, such as an electric motor, of a power release mechanism 133 of the closure latch assembly 210. As shown in Figure 30 , the child lock switch S can be configured in direct electrical communication with the latch controller 155, if desired. Further, the closure latch system 210' is operable to move to a double lock position, also referred to as a lock open position, as shown and discussed with respect to Figure 13 , and therefore, it is not considered necessary to further discuss.

[0086] In Figures 32 to 33In particular, the emergency back-up mechanism (EBM’) is schematically shown to provide the ability to move the closure latch assembly 210 from the latched state to the unlatched state mechanically without the aid of the power actuator 141. Thus, in the event that the power to the power actuator 141 is inadvertently interrupted or the power actuator 141 otherwise becomes mechanically inoperable, by way of example and not limitation, a passenger within the motor vehicle 14 can gain access to and be prepared to reach the emergency back-up mechanism EBM’ such as via the access opening 202 covered and concealed by the rear door handle 226 to manually move the closure latch assembly 210 from the latched state to the unlatched state. The emergency back-up mechanism EBM’ can be provided by a handle, lever, pull tab, pull ring PR, etc. attached to a cable, such as a Bowden cable, which is mechanically coupled to the release lever RL (as shown in Figure 28 In particular, the emergency back-up mechanism (EBM’) is schematically shown to provide the ability to move the closure latch assembly 210 from the latched state to the unlatched state mechanically without the aid of the power actuator 141. Thus, in the event that the power to the power actuator 141 is inadvertently interrupted or the power actuator 141 otherwise becomes mechanically inoperable, by way of example and not limitation, a passenger within the motor vehicle 14 can gain access to and be prepared to reach the emergency back-up mechanism EBM’ such as via the access opening 202 covered and concealed by the rear door handle 226 to manually move the closure latch assembly 210 from the latched state to the unlatched state. The emergency back-up mechanism EBM’ can be provided by a handle, lever, pull tab, pull ring PR, etc. attached to a cable, such as a Bowden cable, which is mechanically coupled to the release lever RL (as shown in

[0087] Referring to Figure 35 When the closure latch system 210’ is in the locked closed position and the child lock closed position, actuation of the rear door handle 226 from the closed position, also referred to as the rest position Figure 32 ) to the normal open position, also referred to as the first deployed position or first position Figure 33 ) moves the closure latch assembly 210 from the latched state to the unlatched state, allowing the rear door 12 to be opened. Movement of the rear door handle 226 to the normal open position triggers the inboard handle switch 253 which is configured in operable communication with the BCM 154 and / or the latch controller 155, wherein at least one of the BCM 154 and / or the latch controller 155 is configured in operable communication with the home position sensor / switch (first sensor) 143, causing the latch controller 155 to send a signal to the motor 141 to drive the power release gear 143 to the release position, as discussed above, moving the closure latch assembly to the unlatched state. The rear door handle 226 can be biased by a rear handle biasing member, such as a suitable spring member SM, to return the rear door handle 226 to the closed position, causing the switch 253 to reset.

[0088] Referring to Figure 36when the closure latch system 210’ is in the lock open position and the child lock open position, actuation of the rear door handle 226 from the closed position Figure 32 to the normal open position Figure 33 does not move the closure latch assembly 210 from the latched state to the unlatched state, thereby keeping the closure latch assembly 210 in the latched state and the rear door 12 in the closed position. In the case of the child lock open, movement of the rear door handle 226 to the normal open position triggers the inboard handle switch 253, which is configured in operable communication with the BCM 154 and / or the latch controller 155, wherein at least one of the BCM 154 and / or the latch controller 155 is configured in operable communication with the child lock position sensor / switch (second sensor) 147, thereby preventing the latch controller 155 from sending a signal to the motor 141 to drive the power release gear 143 to the release position, as discussed above, thereby keeping the closure latch assembly 210 in the latched state. Further, as discussed above with respect to Figure 23 and Figure 24 , manual actuation of the emergency back-up mechanism EBM’ does not move the closure latch assembly 210 to the unlatched state when in the child lock open position.

[0089] Referring to Figure 37 , when the closure latch system 210’ is in the lock open position and the child lock closed position, a single actuation of the rear door handle 226 from the closed position Figure 32 to the normal open position Figure 33 does not move the closure latch assembly 210 from the latched state to the unlatched state, thereby keeping the closure latch assembly 210 in the latched state and the rear door 12 in the closed position. However, a second actuation of the rear door handle 226 from the closed position to the normal open position, also referred to as a double actuation, moves the closure latch assembly 210 from the latched state to the unlatched state, thereby moving the closure latch assembly 210 to the unlatched state, thereby allowing the rear door 12 to be opened, as discussed above with respect to Figure 13 , Figure 14 and Figure 15 (sequences 3-6). In the case of the lock open position and the child lock closed position, movement of the rear door handle 226 to the normal open position in the first actuation triggers the inboard handle switch 253, which is configured in operable communication with the BCM 154 and / or the latch controller 155, wherein at least one of the BCM 154 and / or the latch controller 155 is configured in operable communication with the lock position sensor / switch (third sensor) 149, wherein the first actuation is not sufficient to cause the latch controller 155 to send a signal to the motor 141 to drive the power release gear 143 to the release position, as discussed above with respect to Figure 13As discussed, this keeps the latch assembly 210 in the latched state. However, then, with the lock open position and child lock closed position, the movement of the rear door handle 226 to the normal open position in a second actuation triggers the inside handle switch 253, wherein the second actuation causes the latch controller 155 to send a signal to the motor 141 to drive the power release gear 143 to the release position, as described above for... Figure 14 As discussed, this causes the latching assembly 210 to move from a latched state to an unlocked state. Therefore, the two movements of the rear door handle 226 from its resting original position to its normally open position cause the latching assembly 210 to be dynamically actuated to move from the latched state to the unlocked state.

[0090] Furthermore, when the latching system 210' is in the locked open position and the child lock closed position, in the event of a power interruption, the actuation of the emergency backup mechanism EBM' moves the latching assembly 210 to the unlocked state, as described above. Figure 13 and Figure 14 The user can easily move the rear door handle 226 from a stationary position to what is also called a second deployment position or second position. Figure 34 The emergency open position, wherein the second position exceeds the first position, thereby exposing the access opening 202 so that the user can be ready to touch the emergency pull ring PR. The user can then simply perform a double actuation of the emergency pull ring PR, thereby moving the closing latch assembly 210 to the unlocked state. Thus, even during a power interruption, the rear seat passenger can bypass the power release system via mechanical actuation of the emergency backup mechanism EBM' when the closing latch system 210' is in the locked open position and the child lock is in the closed position.

[0091] According to another aspect of the disclosure, there is provided a method 1000 of constructing a closure latch system 210' for a vehicle door 12. The method 1000 includes a step 1100 of constructing a latch mechanism 31 including a ratchet 32 movable between a striker capture position and a striker release position, and a pawl 36 movable between a ratchet retaining position at which the pawl 36 retains the ratchet 32 in the striker capture position and a ratchet release position at which the pawl 36 allows the ratchet 32 to move to the striker release position. Further, the method includes a step 1200 of constructing a power release mechanism 133 having an original position, a locked position, and a child lock position, and a step 1300 of constructing an inboard door handle 26 in operable communication with the power release mechanism 133, wherein the inboard door handle 26 has a rest position, a first deployment position, and a second deployment position. When the power release mechanism 133 is in the original position, the pawl 36 moves from the ratchet retaining position to the ratchet release position under power of the power release mechanism 133 in response to a single actuation of the inboard door handle 26 from the rest position to the first deployment position, whereas when the power release mechanism 133 is in the locked position, the pawl 36 does not move from the ratchet retaining position to the ratchet release position under power of the power release mechanism 133 in response to the single actuation of the inboard door handle 26 from the rest position to the first deployment position.

[0092] According to another aspect of the method 1000, the step 1400 includes constructing the closure latch system 210' such that when the power release mechanism 133 is in the locked position, the pawl 36 moves from the ratchet retaining position to the ratchet release position under power of the release mechanism 133 in response to a double actuation of the inboard door handle 26 by successively moving the inboard door handle 26 from the rest position to the first deployment position twice.

[0093] According to yet another aspect of the method 1000, the step 1500 includes constructing the closure latch system 210' such that when the power release mechanism 133 is in the child lock position, the pawl 36 is unable to move from the ratchet retaining position to the ratchet release position by actuation of the inboard door handle 26.

[0094] According to yet another aspect of the method 1000, the step 1600 includes constructing an emergency back-up mechanism (EBM') in mechanical communication with the latch mechanism 31, wherein the emergency back-up mechanism EBM' is actuatable to move the pawl 36 from the ratchet retaining position to the ratchet release position without assistance from the power release mechanism 133 when the power release mechanism 133 is in either of the original position and the locked position.

[0095] According to yet another aspect of the method 1000, the step 1700 includes configuring the emergency back-up mechanism EBM' to be accessible via an access opening 202 in an inner door panel of the vehicle door 12.

[0096] According to yet another aspect of the method 1000, the step 1800 includes concealing the access opening 202 with the inboard door handle 26, wherein the access opening 202 is exposed for ready access to the emergency back-up mechanism EBM' by moving the inboard door handle 26 from an unactuated, rest position to an actuated, second, deployed position. It will be appreciated that the access opening 202 is intended to be inaccessible during normal use and further intended to be unobtrusive, such that the aesthetic appearance of the inboard door handle area is satisfactory. As will be appreciated by those skilled in the art upon reading the disclosure provided herein, the access opening 202 is intended to be exposed for access to the emergency back-up mechanism EBM' only when needed, by way of example and without limitation, such as during an emergency, including power release mechanism 133 power failure.

[0097] According to another aspect of the method 1000, the step 1900 includes configuring the inboard door handle 26 to be in electrical communication with the power release mechanism 133, such that the only operable communication between the inboard door handle 26 and the latching mechanism 31 is electrical, and there is no mechanical connection between the inboard door handle 26 and the latching mechanism 31.

[0098] In Figure 39In this regard, an emergency back-up mechanism (EBM") is shown to provide the ability to move the closure latch assembly 310, such as the closure latch assembly 110, 210 discussed above, from the latched state to the unlatched state mechanically from inside the motor vehicle 14 without the aid of a powered actuator, such as the powered actuator 141 discussed above, such as the closure latch system 310' discussed above without the need to repeat the discussion for the closure latch assembly 110, 210. Thus, in the event that the power to the powered actuator is inadvertently interrupted or the powered actuator otherwise becomes inoperable, a passenger inside the motor vehicle 14 can elect to access the emergency back-up mechanism EBM" such as by way of example and not limitation via the access opening 301 covered by the emergency access panel or cover L to move the closure latch assembly 310 from the latched state to the unlatched state manually. The emergency back-up mechanism EBM" can be provided with a pull member PM' such as a handle, lever, pull tab, pull ring, etc. attached to a central cable 302, such as a Bowden cable, having an outer tubular cable conduit 306 configured to slidingly receive a central cable, hereinafter referred to as cable 302, along a cable axis 308 through the outer tubular cable conduit 306. By way of example, the cable 302 extends between a first cable end 311 having the pull member PM' fixed thereto and a second end 313 mechanically coupled to a release lever RL' such as via a suitable connector member 315. Mechanical actuation of the emergency back-up mechanism EBM" from the non-deployed position to the deployed position selectively moves the release lever RL' to move the pawl to the ratchet release position thereby moving the latch assembly 310 from the latched state to the unlatched state. Thus, while the closure latch assembly 310 can be configured to be actuated solely by the inside handle 26 via powered actuation in "normal use" as discussed above for the closure latch assembly 110, in an inoperable state, such as a power interrupted state, the closure latch assembly 310 can be unlatched via manual actuation of the cable assembly 304. The release member can also be provided as a post, lever, plastic cable, metal cable, but only by way of non-limiting example.

[0099] The emergency back-up mechanism EBM" has a pre-loaded bias applied thereto to prevent the emission of a rattle noise when the EBM" is in the non-deployed position (the EBM" is at rest during normal operation of the motor vehicle 14) and while the motor vehicle 14 is moving, regardless of the terrain, including uneven, bumpy terrain. The pre-loaded bias is applied on the cable assembly 304 and, in particular, the bias is applied on the central cable 302. In the illustrated non-limiting embodiment, by way of example and not limitation, the bias can be applied such as by a spring member 317 to apply a constant tension force TF Figure 41B ) on the central cable 302. The spring member 317 is shown configured to apply a spring bias SB directly on the release lever RL', whereby the release lever RL' can be configured to apply the bias on the cable 302. The bias force SB applied by the spring member 317 is shown biasing the release lever RL' in the clockwise direction, as illustrated in Figure 40B 、 Figures 41A to 41B .

[0100] To facilitate maintaining the tension force TF in the cable 302, a stop member 319 can be secured to the central cable 302 such that the bias applied on the cable 302 via the release lever RL' pulls the stop member 319 into engagement with a stop surface 321 that is secured to prevent movement along the cable axis 308 to maintain the tension force TF on the cable 302 when the emergency back-up mechanism EBM" is in the non-deployed position. By maintaining the cable 302 under tension force TF, the rattle and noise generated by the emergency back-up mechanism EBM" when the motor vehicle is driven is prevented. The stop member 319 serves to limit the travel of the release lever RL' at a hard stop position, and thus any further movement of the cable 302 by the release lever RL' when pulled in the clockwise direction as shown in Figure 41A . In the illustrative configuration shown in Figure 41B , the limited travel of the cable 302, for example due to the hard stop position of the cable 302, controls the non-deployed position of the release lever RL' and the release lever RL' does not need to engage a separate hard stop surface, such as a housing bumper 319 provided on the housing of the latch assembly 310. As shown in Figure 41B , the maximum travel of the cable 302 towards the right side when the cable 302 is extended from the tubular cable conduit 306 will control the original unactuated position of the release lever RL'. As a result, a hard stop of the release lever RL', such as the release lever RL' abutting a stop surface provided on the housing of the closed latch assembly 310, is not needed or occurs. As shown in Figure 41B , the hard stop surface 319, for example, does not contact the release lever RL'. With the limited travel of the cable 302, the release lever RL' will be prevented from further rotating (e.g. clockwise) beyond its non-deployed position, for example from itsFigure 41B The position of the release lever RL' is further rotated clockwise (HP). In other words, when in its non-deployed position, the release lever RL' is in a suspended tensioned state. In one possible configuration, the handle assembly, such as a pivoting inside door handle or outside door handle, is not connected to the cable 302 such that the hard stop position of the cable 302 can control the unactuated position of the release lever RL'. In another possible configuration, the handle assembly, such as a pivoting inside door handle or outside door handle, can be connected to the cable 302 such that the hard stop position of the cable 302 can control the unactuated position of the release lever RL'.

[0101] The outer tubular cable conduit 306 extends between an opposite first end 323 and a second end 325, wherein the stop surface 321 can be fixed to the outer tubular cable conduit 306 and in particular to the first end 323. The stop surface 321 can be provided with a circumferentially extending groove 327 configured for fixedly receiving an edge of a panel 329 of the vehicle door therein, thereby preventing undesired relative movement of the stop surface 321 and the outer tubular cable conduit 306 along the cable axis 308. In order to further prevent undesired relative movement of the outer tubular cable conduit 306 along the cable axis 308, the second end 325 of the outer tubular cable conduit 306 can be fixed to a housing 331 of the closure latch assembly 310. Figure 41B ) of the vehicle door therein, thereby preventing undesired relative movement of the stop surface 321 and the outer tubular cable conduit 306 along the cable axis 308. In order to further prevent undesired relative movement of the outer tubular cable conduit 306 along the cable axis 308, the second end 325 of the outer tubular cable conduit 306 can be fixed to a housing 331 of the closure latch assembly 310.

[0102] In the illustrated non-limiting embodiment, the pulling member PM' is provided at the free first end 311 of the cable 302 and the stop member 319 is located between the pulling member PM' and the stop surface 321. The pulling member PM' is configured to be pulled generally along the cable axis 308 to move the stop member 319 away from the stop surface 321 and to move the release lever RL' against the bias exerted by the spring member 317, thereby moving the pawl from the ratchet retaining position to the ratchet release position when the emergency back-up mechanism EBM" is in the deployed position, regardless of the state of the power release mechanism.

[0103] In view of the above discussion regarding EBM", it will be appreciated that the cable 302 is always under tension, regardless of its position, and thus, the rattling of the cable 302 and EBM" can generally be prevented. This is in contrast to a cable 302 that is not under constant tension to prevent relative movement between the cable 302 and the release lever RL', such as for example shown in Figure 43A If there is no pre-load in the EBM", no spring force is exerted on the cable 302 - the situation that would occur is contrasted. The problem that results from no pre-load is potential rattling noise, which is Figure 43BThe remedy is through the application of pre-load via the spring member 317. For example, the rattling or shaking or vibration applied to the closure latch assembly 310 during operation of the vehicle on the road will not result in relative motion between the cable 302 and the release lever RL' which would result in the interaction surfaces of the cable 302 and the release lever RL' being pulled apart and back together, causing a banging sound, for example, the connector member 315 will rattle within the aperture 417 formed in the release lever RL' (as shown by arrow R in Figure 43A The noise emitted from the closure latch assembly 310 when the closure latch is shaken can be prevented or reduced.

[0104] The aperture 417 can be sized to have a large tolerance, shown as gap G in Figure 43A , to be able to receive the connector member 315 (illustratively shown as an L-shaped terminal connector of the cable 302) to facilitate assembly of the cable 302 with the release lever RL'. Illustratively, the connector member 315 inserted into the aperture 417 forms a connection 316 that initially has a tolerance fit, for example, that can be in one or more directions. During such initial assembly step, relative motion can occur between the cable 302 or the connector 315 and the release lever RL', which is shown by the connector member 315 being able to move left or right within the gap G, for example, in Figure 43A . When the coupling between the connector member 315 and the release lever RL' is configured to take a large tolerance, such as when the release lever is in the undeployed position after the initial assembly step is complete, the relative motion between the cable 302 and the release lever RL' is inhibited to prevent the generation of noise during the shaking of the closure latch assembly 310, which can occur during driving, for example, during driving over a pothole, road bumps. As illustratively shown in Figure 43B , the connector member 315 and the inner surface 415 of the aperture 417 can be urged into contact with each other, such as continuous contact. Illustratively, the release lever RL' is shown biased in the direction BD such that the inner surface of the aperture 417 can be urged into contact with the connector member 315. Thus, a tolerance is taken in one direction to prevent movement of the connector member 315 within the aperture 417.

[0105] In Figure 42A and Figure 42B , alternative embodiments are shown in which the stop surface 321 is separate from the outer tubular cable conduit 306, rather than the stop surface 321 being fixed to the first end 323 of the outer tubular cable conduit 306, in which the stop surface 321 can be configured to be fixed to a door panel 329' that is separate from the door panel 329 disposed in the recess 327.

[0106] According to another aspect of the disclosure, as Figure 44 As shown, a method 2000 of constructing a closure latch system 310' for a door 12 of a motor vehicle 14 is provided. The method 2000 includes a step 2100 of constructing a latch mechanism including a ratchet movable between a striker capture position and a striker release position and a pawl movable between a ratchet retaining position at which the pawl retains the ratchet in the striker capture position and a ratchet release position at which the pawl allows the ratchet to move to the striker release position. Further, the method includes a step 2150 of constructing a power release mechanism having an original position, a locked position, and a child lock position and a step 2200 of constructing an inboard door handle in operable communication with the power release mechanism, wherein the inboard door handle has a rest position, a first deployment position, and a second deployment position. The pawl is moved from the ratchet retaining position to the ratchet release position under power of the power release mechanism in response to a single actuation of the inboard door handle from the rest position to the first deployment position when the power release mechanism is in the original position, whereas the pawl is not moved from the ratchet retaining position to the ratchet release position under power of the power release mechanism in response to a single actuation of the inboard door handle from the rest position to the first deployment position when the power release mechanism is in the locked position. Further, the step 2250 includes constructing an emergency back-up mechanism EBM" in mechanical communication with the latch mechanism, wherein the emergency back-up mechanism EBM" is actuatable to move the pawl from the ratchet retaining position to the ratchet release position without assistance from the power release mechanism when the power release mechanism is in either of the original position and the locked position and applying a pre-loaded bias on the emergency back-up mechanism EBM" to prevent a rattle noise from being emitted when in the non-deployed position and while the motor vehicle 14 is moving.

[0107] According to another aspect of the method 2000, the step 2300 includes providing the emergency back-up mechanism EBM" having a cable assembly 304 mechanically coupled to a release lever RL' of the latch mechanism, wherein the cable assembly 304 includes an outer tubular cable conduit 306 and a central cable 302 extending through the outer tubular cable conduit 306 along a cable axis 308 and constructing a bias applied on the central cable 302 as a tension.

[0108] According to another aspect, the method 2000 can include a step 2350 of constructing a spring member 317 to apply the bias directly on the release lever RL' and constructing the release lever RL' to apply the bias on the central cable 302.

[0109] According to another aspect, the method 2000 can include a step 2400 of securing the stop member 319 to the central cable 302 such that a bias applied on the central cable 302 pulls the stop member 319 into engagement with the stop surface 321, which is secured against movement along the cable axis 308, to maintain tension on the central cable 302 when the emergency back-up mechanism EBM" is in the non-deployed position.

[0110] According to another aspect, the method 2000 can include a step 2450 of providing a pulling member PM' at the free end 311 of the central cable 302, wherein the stop member 319 is located between the pulling member PM' and the stop surface 321, and configuring the pulling member PM' to pull generally along the cable axis 308 to move the stop member 319 away from the stop surface 321, thereby moving the release lever RL' against a bias applied by the spring member 317 to move the pawl from the ratchet holding position to the ratchet release position when the emergency back-up mechanism EBM" is in the deployed position, regardless of the state of the power release mechanism.

[0111] According to another aspect, the method 2000 can include a step 2500 of securing the stop surface 321 to the outer tubular cable conduit 306. For example, the stop surface 321 can be configured as a piece of material separate from the outer tubular cable conduit 306 and subsequently attached to the outer tubular cable conduit 306, such as via any suitable adhesive including a welded joint, or the stop surface 321 can be configured as a piece of material integral with the outer tubular cable conduit 306.

[0112] According to another aspect, the method 2000 can include a step 2550 of securing the stop surface 321 to the first end 323 of the outer tubular cable conduit 306 and securing the second end 325 of the outer tubular cable conduit 306 to the housing 331 of the closure latch assembly 310, thereby preventing relative movement of the outer tubular cable conduit 306 along the cable axis 308.

[0113] According to another aspect, the method 2000 can include a step of configuring the emergency back-up mechanism (EBM") to be accessible via the access opening 202 in the inner door panel of the vehicle door 12.

[0114] The foregoing description of implementations has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure to the precise form disclosed. Various elements or features of a specific implementation are generally not limited to the specific implementation unless expressly so limited and, where applicable, can inter-change and be used in other implementations. Various modifications to the implementations can be made as will be apparent to one of ordinary skill in the art, and this application is intended to encompass all such modifications and changes and embodiments thereof. Further, it is intended that all such modifications and changes be included within the scope and range of equivalents of the disclosed implementations.

[0115] Embodiments of the present application can be understood with reference to the following numbered paragraphs:

[0116] 1. A closure latch assembly for a vehicle door, the closure latch assembly comprising:

[0117] a closure latch assembly having a latch mechanism, the latch mechanism including a ratchet and a pawl, the ratchet movable between a striker capture position and a striker release position, the pawl movable between a ratchet hold position, at which the pawl holds the ratchet in the striker capture position of the ratchet, and a ratchet release position, at which the pawl allows the ratchet to move to the striker release position of the ratchet;

[0118] a power release mechanism movable by an actuator between an original position, at which the pawl is movable from the ratchet hold position to the ratchet release position upon a single actuation of the power release mechanism, and at least one of a double pull lock position and a child lock position, at which the pawl is not movable from the ratchet hold position to the ratchet release position upon a single actuation of the power release mechanism or a single actuation of an inboard release member; and

[0119] an emergency back-up mechanism configured to communicate in mechanical communication with the latch mechanism, wherein actuation of the emergency back-up mechanism from a non-deployed position to a deployed position moves the pawl from the ratchet hold position to the ratchet release position regardless of the position of the power release mechanism, wherein the emergency back-up mechanism has a pre-loaded bias exerted on the emergency back-up mechanism to prevent a rattle noise when in the non-deployed position.

[0120] 2. The closure latch system of paragraph 1, wherein the emergency back-up mechanism has a cable assembly mechanically coupled to a release lever of the latch mechanism, wherein the bias is exerted on the cable assembly.

[0121] 3. The closure latch system of paragraph 2, wherein the cable assembly includes an outer tubular cable conduit and a central cable that extends through the outer tubular cable conduit along a cable axis, the bias being exerted on the central cable.

[0122] 4. The closure latch system of paragraph 3, wherein the bias is a tension exerted on the central cable.

[0123] 5. The closure latch system of paragraph 1, wherein the bias is exerted by a spring member.

[0124] 6. The closure latch system of paragraph 5, wherein the spring member exerts the bias directly on the release lever, whereby the release lever exerts the bias on the central cable.

[0125] 7. The closure latch system of paragraph 5, further comprising a stop member secured to the central cable, wherein the bias exerted on the central cable pulls the stop member into engagement with a stop surface that is secured against movement along the cable axis to maintain tension on the central cable when the emergency back-up mechanism is in the non-deployed position.

[0126] 8. The closure latch system of paragraph 7, further comprising a pull member at a free end of the central cable, wherein the stop member is between the pull member and the stop surface, wherein the pull member is configured to pull generally along the cable axis to move the stop member away from the stop surface and move the release lever against the bias exerted by the spring member to move the pawl from the ratchet retaining position to the ratchet release position when the emergency back-up mechanism is in the deployed position.

[0127] 9. The closure latch system of paragraph 8, wherein the stop surface is secured to the outer tubular cable conduit.

[0128] 10. The closure latch system of paragraph 8, wherein the stop surface has a circumferentially extending groove configured to fixedly receive an edge of a panel of the vehicle door in the groove.

[0129] 11. The closure latch system of paragraph 10, wherein the outer tubular cable conduit extends between opposite first and second ends, the stop surface being secured to the first end.

[0130] 12. The closure latch system of paragraph 10, wherein the second end of the outer tubular cable conduit is secured to a housing of the closure latch assembly.

[0131] 13. A method of constructing a closure latch for a vehicle door, the method comprising:

[0132] constructing a latch mechanism including a pawl movable between a striker capture position and a striker release position and a detent movable between a pawl retention position at which the detent retains the pawl in the striker capture position and a pawl release position at which the detent allows the pawl to move to the striker release position;

[0133] constructing a release lever in mechanical communication with the latch mechanism and a release member, wherein the release lever is actuatable to move the detent from the pawl retention position to the pawl release position in response to actuation of the release member; and

[0134] applying a pre-load bias on the release lever to apply tension to the release member.

[0135] 14. The method of paragraph 13, further comprising limiting travel of the release member to prevent the pre-load bias from moving the release lever past an original non-deployed position.

[0136] 15. A closure latch assembly for a vehicle door, the closure latch assembly comprising:

[0137] a latch mechanism including a pawl movable between a striker capture position and a striker release position and a detent movable between a pawl retention position at which the detent retains the pawl in the striker capture position and a pawl release position at which the detent allows the pawl to move to the striker release position; and

[0138] a release lever operably coupled with the detent, wherein actuation of the release lever from a non-deployed position to a deployed position moves the detent from the pawl retention position to the pawl release position; and

[0139] a release member operably coupled to the release lever for actuating the release lever;

[0140] wherein relative movement between the release member and the release lever is inhibited when the release member is coupled to the release lever to prevent noise emission during vibration of the closure latch assembly.

[0141] 16. The closure latch assembly of paragraph 15, wherein the release member is a cable, the cable and the release lever being pushed against one another when the release lever is in the undeployed position.

[0142] 17. The closure latch of paragraph 16, further comprising a spring to bias the release lever against the cable.

[0143] 18. The closure latch of paragraph 17, wherein the release lever is not in contact with a stop surface when the release lever is in the undeployed position.

[0144] 19. The closure latch of paragraph 15, wherein the cable is operably coupled to the release lever via a connection having a tolerance, wherein the release lever in the undeployed position is adapted to take up the tolerance.

[0145] 20. The closure latch of paragraph 15, wherein the undeployed position of the release lever is controlled by an extended position of the cable.

Claims

1. A closing latch system (310') for a vehicle door (12), the closing latch system (310') comprising: A closing latch assembly (310) having a latching mechanism (31) including a ratchet (32) and a pawl (36), the ratchet (32) being movable between a pin-capture position and a pin-release position, and the pawl (36) being movable between a ratchet-hold position and a ratchet-release position, wherein in the ratchet-hold position the pawl (36) holds the ratchet (32) in the pin-capture position, and in the ratchet-release position the pawl (36) allows the ratchet (32) to move to the pin-release position; A release lever (RL) operably connected to the pawl, wherein actuation of the release lever from a non-deployed position to a deployed position moves the pawl from the ratchet holding position to the ratchet release position; and A release member operably coupled to the release lever, the release member being used to actuate the release lever; The relative movement between the release member and the release rod is suppressed when the release member is connected to the release rod to prevent noise from being generated during vibration of the closing latch assembly. The release component is a cable, and the cable and the release lever are pressed against each other when the release lever is in the non-deployment position. The closing latch system further includes a spring (317) for biasing the release lever against the cable, and When the release lever is in the non-deployment position, the release lever does not contact the stop surface (SS), which is disposed in the closing latch assembly to limit the travel of the release member to prevent preload bias from causing the release lever to move past the original non-deployment position.

2. The closing latch according to claim 1, wherein, The release member is operably connected to the release rod via a tolerant connector (316), wherein the release rod in the non-deployed position is adapted to employ the tolerance.

3. The closing latch according to claim 2, wherein, The release rod includes an orifice sized to mate with the release member to a tolerance, wherein the release rod in the non-deployment position is adapted to utilize the tolerance between the orifice and the release member.

4. The closing latch according to claim 1, wherein, The non-deployed position of the release lever is controlled by the unactuated position of the release member.

5. The closing latch according to claim 1, wherein, The cable is housed within a cable conduit, wherein the cable is adapted to contact the cable conduit to establish an unactuated position of the cable.

6. The closing latch according to claim 5, wherein, The cable includes a collar adapted to contact the cable conduit when the cable is in the unacted position.

7. The closing latch according to claim 6, wherein, The release member is adapted to push the collar against the cable conduit when the cable is in the unactuated position.

8. A method for constructing a closing latch for a vehicle door, the method comprising: A latching mechanism is constructed, the latching mechanism including a ratchet movable between a pin-capturing position and a pin-releasing position and a pawl movable between a ratchet-holding position and a ratchet-releasing position, wherein in the ratchet-holding position the pawl holds the ratchet in the pin-capturing position and in the ratchet-releasing position the pawl allows the ratchet to move to the pin-releasing position; A release lever is constructed, which is mechanically connected to the latching mechanism and the release member, wherein the release lever can be actuated to move the pawl from the ratchet holding position to the ratchet releasing position in response to actuation of the release member; Provide a cable connected to the release lever to actuate the release lever; A preload bias is applied to the release lever to apply tension to the release member; and Limiting the travel of the release member prevents the preload bias from causing the release lever to move past its original non-deployment position, such that by limiting the travel of the cable with a cable hard stop position, the release lever does not need to engage with a hard stop surface provided on the latch housing.

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