Locking mechanism assembly with unidirectional force release actuator with safety blocking arrangement

Abstract

A closure lock assembly includes a force release gear configured to be driven by a motor in a first direction from a home position to a release position, wherein a pawl releases a ratchet gear to allow the ratchet gear to move to a striker release position and in the first direction back to the home position, wherein a sensor signals the motor to de-energize when the force release gear returns to the home position. If the pawl does not release the ratchet gear, the force release gear is driven by the motor in a second direction opposite the first direction to cause the pawl to release the ratchet gear to allow the ratchet gear to move to the striker release position.

Description

AREA

[0001] The present disclosure generally relates to power door systems for motor vehicles. More specifically, the present disclosure is directed to a power door system equipped with a power latch assembly having a unidirectional motor and a power release gear having sensing and positive stop features for stopping the power release gear during power release of a pawl relative to a ratchet gear of the power latch assembly during normal release, and having bidirectional rotation for emergency release. STATE OF THE ART

[0002] Given increased consumer demand for motor vehicles equipped with modern convenience features, many current vehicles are now equipped with power-operated locking assemblies that can be operated via passive keyless entry systems to enable power-operated closing and power-operated releasing of the locking assemblies without the use of conventional manual entry mechanisms. While such power-operated locking assemblies provide the desired functionality under normal operating conditions, further improvements are desired to ensure that the features of the power-operated locking assemblies achieve and maintain their intended position and functionality, including during emergency conditions such as a crash, while also having the fewest possible components and being economical to manufacture.

[0003] In light of the above, there remains a desire to develop alternative power-operated door locking assemblies that address and overcome the limitations associated with known power-operated door locking assemblies to provide improved functionality while minimizing the cost and complexity associated with such advancements. SUMMARY

[0004] One aspect of the present disclosure is to provide a closure latch assembly for a vehicle closure door, the closure latch assembly having a minimal number of components and being economical to manufacture.

[0005] A closure latch assembly for a vehicle closure door is provided. The closure latch assembly includes a power release gear configured to be driven by the motor from a home position to a release position and back to the home position, and a locking mechanism including a ratchet gear and a pawl. The ratchet gear is movable between a primary striker receiving position and a striker releasing position. The pawl is movable between a ratchet holding position, in which the pawl holds the ratchet gear in the primary striker receiving position, and a ratchet releasing position, in which the pawl permits movement of the ratchet gear to its striker releasing position.When energized in a first actuation, the motor drives the power release gear in a first direction from the home position to the release position, whereupon the power release gear operatively drives the pawl from the ratchet holding position to the ratchet release position, allowing the ratchet to move from the primary striker receiving position to the striker release position. The motor drives the power release gear in the first direction back to the home position when it causes the pawl to move to the ratchet release position and the ratchet to move from the primary striker receiving position to the striker release position.

[0006] According to another aspect, a sensor is configured to signal that the motor should be turned off when the power release gear is returned to the home position.

[0007] According to another aspect, a ratchet stop lug is attached to the ratchet gear, and a force release gear stop lug is attached to the force release gear, wherein if the sensor does not signal that the motor should be turned off when the force release gear reaches the home position, the force release gear stop lug engages the ratchet stop lug to stop the force release gear from being driven beyond the home position.

[0008] In another aspect, if the sensor does not signal that the engine should be shut off when the power release gear returns to the home position, the ratchet is capable of returning from the striker release position to the primary striker receiving position, with the pawl returning to the ratchet holding position.

[0009] According to another aspect, when the pawl does not move from the ratchet holding position to the ratchet release position and the ratchet does not move from the primary striker receiving position to the striker release position while the power release gear rotates in the first direction from the home position to the release position, in a second actuation, the motor is energized to drive the power release gear in a second direction, whereupon the power release gear operatively drives the pawl from the ratchet holding position to the ratchet release position such that the ratchet moves from the primary striker receiving position to the striker release position.

[0010] In another aspect, the force release gear applies a first force to the pawl while rotating in the first direction, and the force release gear applies a second force to the pawl while rotating in the second direction, the second force being greater than the first force.

[0011] In another aspect, the power release gear rotates through a first range of degrees while rotating in the first direction, and the power release gear rotates through a second range of degrees while rotating in the second direction, the second range of degrees being greater than the first range of degrees.

[0012] According to another aspect, if the pawl does not move from the ratchet holding position to the ratchet release position and the ratchet does not move from the primary striker receiving position to the striker release position while the power release gear rotates in the second direction to a release position, the motor is energized in a third actuation to drive the power release gear a second time in the first direction.

[0013] In another aspect, the power release gear, on the first occurrence, rotates through a first range of degrees while rotating in the first direction and through a second range of degrees while rotating in the second direction, the second range of degrees being greater than the first range of degrees, and the power release gear, on the second occurrence, rotates through a third range of degrees while rotating in the first direction, the third range of degrees being equal to or greater than the second range of degrees.

[0014] In another aspect, the force release gear, on the first occurrence, applies a first force to the pawl while rotating in the first direction and a second force to the pawl while rotating in the second direction, the second force being greater than the first force, and the force release gear, on the second occurrence, applies a third force to the pawl while rotating in the first direction, the third force being equal to or greater than the second force.

[0015] According to another aspect, the motor is powered by a primary power source during the first actuation and by a backup power source during the second actuation.

[0016] According to another aspect, the motor is powered by a primary power source during the first actuation and by a backup power source during the third actuation.

[0017] According to a further aspect, the motor is supplied with energy by the backup power source during the second actuation.

[0018] According to another aspect, a method is provided for actuating a closure lock assembly in a normal operating condition and in an emergency operating condition. The method includes: during the normal operating condition, energizing a motor in a first actuation to rotate a force release gear in a first direction to operably move a pawl from a ratchet holding position to a ratchet releasing position to cause a ratchet to move from a primary striker receiving position to a striker releasing position.If the pawl cannot be moved from the ratchet holding position to the ratchet release position in the normal operating condition, in the emergency operating condition the motor is energized in a second actuation to rotate the power release gear in a second direction opposite to the first direction to operatively move the pawl from the ratchet holding position to the ratchet release position to move the ratchet from the primary striker receiving position to the striker release position.

[0019] According to another aspect, the method further includes causing the force release gear to apply a first force to the pawl while rotating in the first direction and causing the force release gear to apply a second force to the pawl while rotating in the second direction, the second force being greater than the first force.

[0020] According to another aspect, the method further includes causing the force release gear to rotate through a first range of degrees while rotating in the first direction and causing the force release gear to rotate through a second range of degrees while rotating in the second direction, wherein the second range of degrees is greater than the first range of degrees.

[0021] According to another aspect, the method further includes, during the emergency operating condition, energizing the motor in a third actuation after the second actuation to rotate the force release gear in the first direction to operably move the pawl from the ratchet holding position to the ratchet releasing position to move the ratchet from the primary striker receiving position to the striker releasing position.

[0022] According to another aspect, the method further includes causing the force release gear to apply a first force to the pawl while rotating in the first direction in response to the first actuation, and causing the force release gear to apply a second force to the pawl while rotating in the second direction in response to the second actuation, the second force being greater than the first force, and causing the force release gear to apply a third force to the pawl while rotating in the first direction in response to the third actuation, the third force being equal to or greater than the second force.

[0023] According to another aspect, the method further includes causing the force release gear to rotate through a first range of degrees while rotating in the first direction during the first actuation, and causing the force release gear to rotate through a second range of degrees while rotating in the second direction, wherein the second range of degrees is greater than the first range of degrees, and causing the force release gear to move through a third range of degrees while rotating in the first direction during the third actuation, wherein the third range of degrees is equal to or greater than the second range of degrees.

[0024] In another aspect, the method further includes powering the motor with a primary power source during the normal operating condition and powering the motor with a backup power source during the emergency operating condition.

[0025] Further areas of applicability will become apparent from the description provided herein. As noted, the description and any specific examples in this summary are for illustrative purposes only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The present disclosure will now be described, by way of example only, with reference to the accompanying drawings. Fig. 1 is a perspective view of a motor vehicle having a vehicle closure door equipped with a closure latch assembly constructed in accordance with several aspects of the disclosure; Fig. 2 is a perspective view of a closure locking assembly of Fig. 1 according to one aspect of the disclosure, showing a ratchet gear of the closure locking assembly in a primary striker receiving position; Fig. 2A is an exploded view of Fig. 2; Fig. 3 is a perspective view of the ratchet illustrating a ratchet stop tab attached thereto, with a power release gear having a power release gear stop tab configured for selective engagement with the ratchet stop tab; Fig. 4A is a front view of the closure lock assembly in a locked position corresponding to the ratchet gear in the primary striker receiving position; Fig. 4B is a rear view of Fig. 4A; Fig. 5A and Fig. 5B resemble Fig. 4A and 4B, respectively, illustrate an initial phase of a motor of the closure lock assembly being energized to drive a force release gear from a home position in a first direction to a release position and a pawl being driven from a ratchet holding position to a ratchet releasing position; Fig. 6A and Fig. 6B resemble Fig. 5A and 5B respectively illustrate an initial phase of release of the ratchet to move from the primary striker receiving position to a striker releasing position; Fig. 7A and Fig. 7B resemble Fig. 6A and 6B respectively illustrate the locking gear being moved to the striker release position; Fig. 8A and Fig. 8B resemble Fig. 7A and 7B respectively illustrate how the power release gear continues to rotate in the first direction toward a reset home position; Fig. 9A and Fig. 9B resemble Fig. 8A and 8B respectively illustrate a sensor detecting that the power release gear has been moved to the reset home position, the sensor signaling that the motor should be turned off to stop rotation of the power release gear; Fig. 10A and Fig. 10B resemble Fig. 8A and 8B, respectively, illustrate the power release gear being moved to engage the stop tab of the power release gear with the ratchet stop tab when the sensor does not signal that the engine should be shut down due to a sensor malfunction, thereby maintaining the pawl in the correct position to return to the ratchet holding position when the ratchet returns to the primary striker receiving position; Fig. 11A and Fig. 11B resemble Fig. 10A and 10B, respectively, illustrate the ratchet returning to the primary striker receiving position under a striker impact force, with the pawl returning to the ratchet holding position during the sensor malfunction; Fig. 12A and Fig. 12B illustrates a release failure in releasing the pawl from the ratchet holding position to the ratchet releasing position during a first normal operation; Fig. 13A and Fig. 13B illustrates a second release operation under an emergency operation wherein the motor of the closure lock assembly is energized to drive the force release gear in a second direction opposite to the first direction; Fig. 14A and Fig. 14B illustrate a third release operation under an emergency operation, wherein the motor of the closure lock assembly is energized to drive the force release gear in the first direction opposite to the second direction; and Fig. 15 illustrates a flowchart of a method for actuating a closure lock assembly in a normal operating condition and in an emergency operating condition according to another aspect of the disclosure. DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

[0027] With reference first to Fig. 1, a closure latch assembly, also referred to as a closure lock or latch assembly 10, for a motor vehicle closure, such as a swinging door shown as a rear door 12, of a motor vehicle 14 is shown, by way of example and without limitation, positioned along a closure surface portion 16 of the door 12 and is configured to releasably engage and receive a striker 18 fixed to a vehicle body 22 for extending into a door opening 20 formed in the vehicle body 22 in response to movement of the door 12 from an open position to a closed position. The door 12 is shown including an exterior door handle 24 and an interior 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 understood that a similar closure latch assembly is provided in association with a front door 13 of a vehicle 14, which is shown with its own exterior door handle 25.

[0028] With reference to Fig. 2 to 5, a non-limiting example embodiment of the closure locking assembly 10 and its internal components, including a locking mechanism 31 thereof, is shown, wherein the locking mechanism 31 of the closure locking assembly 10 in Fig. 2 in a closed, locked position. The locking mechanism 31 shown includes a ratchet 32 ​​and a pawl 36. The ratchet 32 ​​is pivotally mounted on a plate segment, also referred to as a frame plate 28, of a lock housing and includes a ratchet slot 34 alignable with a fish-mouth slot 30 formed in the frame plate 28. The ratchet 32 ​​is movable between a primary closed or "striker receiving" position ( Fig. 2, 2A, 4A to 5B and Fig. 11A to 11B), in which the striker 18 is held by being received in the ratchet slot 34 in the fish mouth slot 30, and an open or "striker release" position ( Fig. 7A to 10B), in which the striker 18 can be freely released from the ratchet slot 34 and the fishmouth slot 30. The ratchet 32 ​​is biased toward its striker release position by a ratchet biasing member 32a, such as a ratchet spring. The pawl 36 is pivotally mounted and is movable between a secured, ratchet-retaining position, also referred to as a "closed" position, in which the pawl 36 locates and holds the ratchet 32 ​​in its striker-receiving position, and an unsecured, ratchet-releasing position, also referred to as an "open" position, in which the pawl 36 is positioned to permit movement of the ratchet 32 ​​to its striker release position, such as under a bias applied to the ratchet 32 ​​by a ratchet spring.A pawl biasing member 36a, such as a pawl spring, is operable to normally bias the pawl 36 toward its open position.

[0029] A lock release mechanism may include a power-driven actuator 38, such as an electric motor, including a motor shaft with a worm gear 40 attached thereto and a force release gear 42 driven by the worm gear 40 of the electric motor 38, which serves to drive an actuator release lever 44, also referred to as an actuator lever or force release member or release member, via engagement of a cam member 41 mounted on the force release gear 42 for eccentric rotation about a central rotational axis A1 ( Fig. 2A) of the force release gear 42, wherein the cam element 41 is mounted in a receptacle 44b ( Fig. 2A) of the release lever 44. The release member 44, in turn, serves to drive a locking release lever 46, shown as a pawl lever and also referred to as a release lever, which in turn drives the pawl 36 from its ratchet-retaining position to its ratchet-releasing position to provide a force-releasing function of the locking mechanism 31. The release lever 46 has a driven feature attached thereto, shown as a pawl lever pin and also referred to as a driven pin 46a, the driven pin 46a being received by an elongated slot 44a of the release member 44 for lost motion therein.During movement of the release member 44 in response to movement of the power release gear 42 in the first direction D1 from the home position, the driven pin 46a is drivingly engaged by one end of the slot 44a so that the release lever 46a is driven to cause the pawl 36 to move from the ratchet holding position to the ratchet releasing position against the bias exerted by the pawl biasing member 36a.

[0030] A sensor 50, such as a Hall sensor, is configured to be in operative communication with the motor 38 to detect a home position of the force release gear 42, such as by detecting a magnet 51 fixed to the force release gear 42. The sensor 50 communicates with a controller 54 configured to control the operation of the motor 38. The controller 54 may be a combination of hardware and / or software, implemented, for example, in the form of a microprocessor and other circuitry or other electronic circuitry, according to non-limiting examples.In operation, the force release gear 42 is configured to be driven by the motor 38 in a single rotational direction, referred to as the first rotational direction D1, during normal operation (when no increased load is applied to the entire locking mechanism 31 beyond that anticipated or otherwise expected during normal use), from a rest position, also referred to as the home position, to a release position, and then continue to rotate in the same first direction D1 to a reset position corresponding to the home position. Accordingly, the force release gear 42 rotates only in the first direction D1 to perform a release and reset function. During rotation in the first direction D1, the force release gear 42 rotates a first range of degrees, also referred to as the first distance d1, from the rest position to the release position.The force release gear 42 operatively exerts (directly or indirectly via intermediate components, i.e., the actuator release lever 44 and the lock release lever 46) a first force F1 on the pawl 36 while rotating in the first direction D1.

[0031] The ratchet includes a ratchet stop lug 52, also referred to as a safety block feature. The ratchet stop lug 52 may be formed from a separate piece of material from the ratchet 32 ​​and subsequently secured thereto, as shown in Fig. 2A and Fig. 3. Otherwise, it is contemplated herein that the ratchet stop lug 52 may, if desired, be formed as a monolithic piece of material with the ratchet 32. Regardless, the ratchet stop lug 52 is secured to the ratchet 32 ​​for movement therewith.

[0032] The force release gear 42 is configured in normal operation to rotate when energized in response to a release command by the motor 38 in the single first direction of rotation D1 from a rest position, also referred to as the home position ( Fig. 4A and Fig. 4B), in which the pawl 36 holds the locking gear 32 in the primary striker receiving position, into a release position ( Fig. 5A and Fig. 5B), in which the pawl 36 is to be moved into the ratchet release position against the preload exerted by the pawl preload element 36a, and the ratchet 32 ​​is to be freely moved into the striker release position under the preload exerted by the ratchet preload element 32a. Subsequently, the force release gear 42 continues to rotate in the same first direction D1 ( Fig. 6A to 9B) back to the reset position, which corresponds to the starting position ( Fig. 9A and Fig. 9B). Attached to the force release gear 42 is a force release gear stop tab 48, also referred to as a safety block feature, which is only activated in the event of a malfunction of the sensor 50 provided to detect the return of the force release gear 42 to its home position. The sensor 50 is configured to signal the motor 38, via the controller 54, to shut down when the force release gear 42 reaches the home position. By way of example and without limitation, the sensor 50 may be configured to detect the position of a magnet 51 attached to the force release gear 42, allowing the sensor 50 to detect when the force release gear 42 is in a desired position, such as the home position, whereupon the sensor 50 signals that the motor 38 should shut down.

[0033] If the sensor 50 does not signal that the motor 38 should be switched off when the force release gear 42 returns from the release position to the starting position, which can happen, for example, if the sensor 50 and / or the magnet 51 become inoperable, such as through damage, the stop lug of the force release gear 48 engages, by way of example and without limitation, the stop lug 52 attached to the ratchet gear 32 ( Fig. 10B) to prevent the power release gear 38 from being continuously driven in the first direction D1 beyond and away from the initial position. Thus, while the power release gear 38 is held in the initial position, as shown in Fig. 11A and Fig. 11B, the ratchet gear 32 is free to return to the primary striker receiving position, with the pawl 36 returning to the ratchet holding position under the bias exerted by the pawl biasing member 36a when the vehicle closure door 12 is closed. After the ratchet gear 32 has been returned to a fully closed position, so that the ratchet stop lug 52 is moved out of the path of travel of the stop lug of the force release gear 48, as shown in Fig. 11B, upon subsequent activation of the motor 38 in direction D1, d1 to again power release the latch, the power release gear 42 is not obstructed by this ratchet stop lug 52. Consequently, in one possible configuration, the latch 10 is configured to have a unidirectional power release chain, wherein rotation of the power release gear and rotation of the motor 38 during a normal mode (e.g., a non-emergency mode) can be provided in a single direction, illustratively shown as direction D1, d1. As a result, control of the motor 38, requiring, for example, an H-bridge, is not required because the motor 38 is controlled only by provided on / off power supply signals and not by reversing the power supply polarity, thereby reducing electronics and control features.In addition, no return or recoil spring is required to return to an initial position, and reverse drive of the motor 38 under this spring preload is also not required, thus eliminating a spring component as well as a hard stop / impact return noise caused by a return spring each time the motor 38 is deactivated.

[0034] Furthermore, the control 54 ( Fig. 2), as above for the Fig. 5A and Fig. 5B, the motor 38 is to be energized to reverse the direction of rotation and rotate the power release gear 42 in a second direction D2 ( Fig. 13A) opposite to the first direction D1 if the pawl 36 does not move from the ratchet holding position to the ratchet release position and the ratchet 32 ​​does not move from the primary striker receiving position to the striker release position when the force release gear 42 is rotating during normal operation ( Fig. 12A and Fig. 12B) over the first distance d1 in the first direction D1. During rotation of the force release gear 42 in the second direction D2, the force release gear 42 operatively exerts (directly or indirectly through intervening components, i.e., release member, also referred to as actuator release lever 44, and release lever, also referred to as lock release lever 46) a second force F2 ( Fig. 13A) on the pawl 36, thereby moving the pawl 32 from the ratchet holding position to the ratchet release position against the bias exerted by the pawl biasing member 36a, so that the ratchet 32 ​​moves from the primary striker receiving position to the striker release position under the bias exerted by the ratchet biasing member 32a. The lack of movement of the pawl 36 from the ratchet holding position to the ratchet release position and the lack of movement of the ratchet 32 ​​from the primary striker receiving position to the striker release position when the power release gear 42 rotates in the first direction D1 during normal operation ( Fig. 12A and Fig. 12B), may be determined, for example, by the sensor 50 not detecting that the force release gear 42 returns to the home position after the motor 38 is activated, and / or by a sensor not detecting that the position of the pawl 36 has moved to the ratchet release position, and / or by a sensor not detecting that the ratchet gear 32 has rotated to the open striker release position, and / or by a sensor detecting that the motor 38 is in a locked state. During rotation in the second direction D2, the force release gear 42 rotates a second range of degrees, also referred to as a second distance d2, from the rest position to the release position, wherein the second distance d2 is greater than the first distance d1.Since the second distance d2 is greater than the first distance d1, the second force F2 is greater than the first force F1 and thus overcomes the resistance preventing the intended release of the closure locking assembly 10 during the first normal release attempt of the . Fig. 12A and Fig. 12B. The greater distance d2 traveled by the force release gear 42 creates an increase in inertia that contributes at least in part to the increase in the second force F2 relative to the first force F1. To increase the travel distance of the force release gear 42 during reverse operation of the motor, such as may occur during emergency operation, the signal from the sensor 50 may be ignored by the controller 54 so as not to stop the rotation of the force release gear 42 in the home position, allowing the force release gear 42 to develop full rotational speed and inertia from its previous stopped position, e.g., in the stall position.

[0035] If for any reason the closure locking assembly 10 is not released after completion of the Fig. 13A and Fig. 13B, which can be easily determined by the above-mentioned position detection sensors and the controller 54, a third actuation of the motor 38 can be performed via a signal from the sensor 50. As in Fig. 14A and Fig. 14B, the third actuation causes the motor 38 to again reverse direction to rotate in the first direction D1, whereupon the force release gear 42 operatively applies (directly or indirectly through intervening components, i.e., actuator release lever 44 and latch release lever 46) a third force F3 to the pawl 36, thereby moving the pawl 32 from the ratchet holding position to the ratchet releasing position, such that the ratchet gear 32 moves from the primary striker receiving position to the striker releasing position. During rotation in the first direction D1, the force release gear 42 rotates a third range of degrees, also referred to as a third distance d3, from the rest position to the release position, wherein the third distance d3 is greater than the first distance d1 and at least equal to, or preferably greater than, the second distance d2.Since the third distance d3 is greater than the first distance d1 and equal to or greater than the second distance d2, the third force F3 is greater than the first force F1 and equal to or greater than the second force F2, thereby maximizing the ability to overcome the resistance that prevents the intended release of the closure lock assembly 10 during normal release of . Fig. 12A and Fig. 12B. The greater distance d3 traveled by the force release gear 42 creates an increase in inertia which contributes at least in part to the increase in the third force F3 relative to the first force F1 and is desirably greater than the second force F2.

[0036] In another aspect, the power used to power the motor 38 during the second and third actuations to power the power release gear 42 in the emergency condition may be provided by a backup power source 56 other than the main vehicle battery, also referred to as a primary power source, used during normal operation. The backup power source 56 may be provided as a fully charged supercapacitor, thereby having a full charge of power that may not be available from the main vehicle battery, particularly in an emergency condition, such as a crash condition. The backup power source 56 may be arranged in operative communication with the sensor 50 and / or a vehicle ECU 54, as desired.

[0037] In Fig. 15 illustrates a flowchart of a method 1000 for operating a closure lock assembly 10 in a normal operating condition and in an emergency operating condition according to another aspect of the disclosure. The method 1000 includes a step 1100 for operating the closure lock assembly 10 in a normal mode, as discussed above and in Fig. 12A and Fig. 12B. In normal operation, a step 1200 is included in which the motor 38 is energized to rotate it in a single direction, thereby rotating the force release gear 42 a first distance d1 in a first direction D1, whereupon a first force F1 is applied across the entire locking mechanism 31. Then, if a sensor 50 detects an emergency condition, such as a crash condition, in which the locking mechanism 31 remains in a locked state in a step 1300, a step 1400 is executed to actuate the closure latch assembly 10 in an emergency mode, as discussed above and in Fig. 13A and Fig. 13B, is performed, whereupon, in step 1500, the motor 38 is caused to rotate in a second direction, thereby driving the force release gear 42 a second distance d2 in a second direction D2, whereupon a second force F2 is applied throughout the locking mechanism 31. The second distance d2 is greater than the first distance d1, and thus the second force F2 is greater than the first force F1, due at least in part to an increase in inertia. A next step 1600 determines whether the closure lock assembly 10 is moved from the locked state to an unlocked state. For example, if it is detected via the sensor 50 that the closure lock assembly 10 remains in the locked state, a step 1700 is performed in which the motor 38 is energized to rotate in the first direction ( Fig. 14A and Fig.14B), whereby the force release gear 42 is rotated a third distance d3 in the first direction D1, whereupon a third force F3 is applied throughout the locking mechanism 31, the third force F3 being equal to or greater than the second force F2. A next step 1800 determines whether the shutter lock assembly 10 is moved from the locked state to an unlocked state. For example, if it is detected via the sensor 50 that the shutter lock assembly 10 remains in the locked state, step 1900 returns to step 1500 to repeat its operation, which may continue until the shutter lock assembly 10 is unlocked.

Claims

[1] A locking assembly (10) for a vehicle closure flap (12), comprising: an engine (38); a force release gear (42) configured to be driven by the motor (38) from a home position to a release position and back to the home position; and a locking mechanism (31) including a ratchet (32) and a pawl (36), the ratchet (32) being movable between a primary striker receiving position and a striker releasing position, the pawl (36) being movable between a ratchet holding position in which the pawl (36) holds the ratchet (32) in the primary striker receiving position and a ratchet releasing position in which the pawl (36) allows the ratchet (32) to move to its striker releasing position, wherein the motor (38), when energized in a first actuation, drives the force release gear (42) in a first direction (D1) from the home position to the release position, whereupon the force release gear (42) operatively drives the pawl (36) from the ratchet holding position to the ratchet release position, so that the ratchet gear (32) can move from the primary striker receiving position to the striker release position, wherein the motor (38), after causing the pawl (36) to move to the ratchet release position and the ratchet gear (32) to move from the primary striker receiving position to the striker release position, drives the power release gear (42) in the first direction back to the home position. [2] The closure lock assembly (10) of claim 1, further including a sensor (50) configured to signal the motor (38) to be turned off when the force release gear (42) is returned to the home position. [3] The closure latch assembly (10) of claim 2, further including a ratchet stop tab (52) attached to the ratchet gear (32) and a force release gear (48) stop tab attached to the force release gear (42), wherein if the sensor (50) does not signal that the motor (38) should be turned off when the force release gear (42) reaches the home position, the force release gear (48) stop tab engages the ratchet stop tab (52) to stop the force release gear (42) from being driven beyond the home position. [4] The closure lock assembly (10) of claim 3, wherein, if the sensor (50) does not signal that the motor (38) should be turned off when the force release gear (42) reaches the home position, the ratchet gear (32) is capable of returning from the striker release position to the primary striker receiving position, with the pawl (36) returning to the ratchet holding position. [5] The closure latch assembly (10) of any one of claims 1 to 4, wherein, when the pawl (36) is not moving from the ratchet holding position to the ratchet release position and the ratchet gear (32) is not moving from the primary striker receiving position to the striker release position while the power release gear (42) is rotating in the first direction (D1) from the home position to the release position, the motor (38) is energized in a second actuation to drive the power release gear (42) in a second direction (D2), whereupon the power release gear (42) operatively drives the pawl (36) from the ratchet holding position to the ratchet release position such that the ratchet gear (32) moves from the primary striker receiving position to the striker release position. [6] The closure lock assembly (10) of claim 5, wherein the force release gear (42) applies a first force (F1) to the pawl (36) while rotating in the first direction (D1) and a second force (F2) to the pawl (36) while rotating in the second direction (D2), the second force (F2) being greater than the first force (F1). [7] The closure locking assembly (10) of claim 5 or 6, wherein the force release gear (42) rotates over a first range of degrees when rotating in the first direction (D1) and over a second range of degrees when rotating in the second direction (D2), the second range of degrees being greater than the first range of degrees. [8] The closure latch assembly (10) of any one of claims 5 to 7, wherein, when the pawl (36) does not move from the ratchet holding position to the ratchet releasing position and the ratchet gear (32) does not move from the primary striker receiving position to the striker releasing position upon rotation of the force release gear (42) in the second direction (D2), the motor (38) is energized in a third actuation to drive the force release gear (42) a second time in the first direction (D1). [9] The closure lock assembly (10) of claim 8, wherein the force release gear (42) rotates over a first range of degrees while rotating in the first direction (D1) on the first occurrence and over a second range of degrees while rotating in the second direction (D2), the second range of degrees being greater than the first range of degrees, and wherein the force release gear (42) rotates over a third range of degrees while rotating in the first direction (D1) on the second occurrence, the third range of degrees being equal to or greater than the second range of degrees. [10] The closure latch assembly (10) of claim 9, wherein the force release gear (42) on the first occurrence applies a first force (F1) to the pawl (36) while rotating in the first direction (D1) and a second force (F2) to the pawl (36) while rotating in the second direction (D2), the second force (F2) being greater than the first force (F1), and wherein the force release gear (42) on the second occurrence applies a third force (F3) to the pawl (36) while rotating in the first direction (D1), the third force (F3) being equal to or greater than the second force (F2).

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