Vehicle door lock apparatus

This application claims the priority benefit of Japanese Patent Application No. 2016-142211 filed on Jul. 20, 2016, the entire contents of which are incorporated by reference as if fully set forth herein.

The present invention relates to a vehicle door lock apparatus.

Japanese Patent Laid-Open No. 2002-129806 (Patent Literature 1) discloses a known vehicle door lock apparatus that includes a housing, a fork, a pawl, a first lever, and a second lever. More specifically, the first lever is an open link and the second lever is an open lever.

The housing includes a base plate. The base plate is fixed such that a fixing surface thereof contacts a door that is openable and closable with respect to a vehicle frame, to which a striker is affixed. An entry opening, into which the striker can enter, is formed in the base plate.

As illustrated, e.g., in FIG. 4 of JP 2002-129806, the fork is pivotably provided on the base plate. The fork is displaceable to a latched position, where the fork retains the striker in the entry opening, and to an unlatched position, where the fork allows the striker to separate from the entry opening. The pawl is pivotably provided on the base plate. The pawl fixes or releases the fork. A lift lever is affixed to the pawl so as to integrally rotate therewith. As illustrated in FIG. 4 of JP 2002-129806, the pawl is supported so as to be pivotable about a pawl axis that is substantially orthogonal to the fixing surface of the base plate.

The first lever is displaceably provided in the housing. The first lever can be displaced upward to come into contact with the lift lever and thereby act on the pawl and is capable of causing the pawl to release the fork. The second lever is pivotably provided in the housing. One end of the second lever is coupled to an exterior door handle via a transmission rod. The other end of the second lever is coupled to the first lever. As illustrated, e.g., in FIGS. 2 and 5 , of JP 2002-129806, the second lever pivots in response to an opening operation being performed on the exterior door handle to act on the first lever and is capable of displacing the first lever upward.

As illustrated in FIG. 2 of JP 2002-129806, a linkage is formed at one end of the second lever. The lower end of the transmission rod is coupled to the linkage. As illustrated in FIG. 4 of JP 2002-129806, the pivot axis of the second lever is located frontward with respect to the pawl and extends in parallel to the pawl axis.

In this known vehicle door lock apparatus, when the transmission rod descends in response to the opening operation being performed on the exterior door handle and the lower end of the transmission rod pushes down the linkage of the second lever, the second lever pivots and the first lever, which is displaced upward, comes into contact with the lift lever. As a result, the pawl releases the fork and it is possible to open the door.

Incidentally, such a vehicle door lock apparatus may generally be used as both a vehicle door lock apparatus mounted on a front door and a vehicle door lock apparatus mounted on a rear door. Depending on the shape of the door on which the vehicle door lock apparatus is mounted, as illustrated in FIG. 1 of JP 2002-129806, the vehicle door lock apparatus is sometimes mounted on the door such that the fixing surface of the base plate is inclined relative to the vertical direction. In such a case, a plane of rotation, which contains an arcuate trajectory traced by the linkage of the second lever when it pivots in response to the opening operation being performed on the exterior door handle, is located farther in a frontward direction of the vehicle frame than the fixing surface of the base plate and is parallel to the fixing surface. Therefore, the plane of rotation is also inclined relative to the vertical direction.

Therefore, this plane of rotation is inclined relative to a plane that contains an arcuate trajectory traced by the upper end of the transmission rod when it pivots in response to the opening operation being performed on the exterior door handle (i.e. when the exterior door handle is manually pulled to open the door). Due to this arrangement, the transmission rod might be distorted when the opening operation is being performed on the exterior door handle; distortion of the transmission rod could lead to a deterioration of operation sensitivity (manual responsiveness), a loss of transmission stroke, etc. Therefore, in such a known vehicle door lock apparatus, a distorted transmission rod may impair the smooth transmission of the opening operation (pulling stroke) from the exterior door handle to the second lever via the distorted transmission rod.

In view of these circumstances, an object of the present teachings is to provide an improved vehicle door lock apparatus that can transmit an opening operation from an exterior door handle to a second lever via a transmission rod and can perform the opening of the door in a satisfactory manner.

In one embodiment of the present teachings, a vehicle door lock apparatus includes:

a housing including a base plate fixed in a state in which a fixing surface of the base plate abuts against a door that is openable and closable with respect to a vehicle frame, to which a striker is fixed, the base plate also having an entry opening, into which the striker can enter, formed therein;

a fork pivotably provided on the base plate and that is displaceable to a latched position, where the fork retains the striker in the entry opening, and to an unlatched position, where the fork allows the striker to separate from the entry opening;

a pawl pivotably provided in the base plate, the pawl fixing or releasing the fork;

a first lever displaceably provided in the housing, the first lever being capable of acting on the pawl when it is displaced and causing the pawl to release the fork; and

a second lever pivotably provided in the housing, one end of the second lever being coupled to an exterior door handle via a transmission rod, the second lever being capable of acting on the first lever and displacing the first lever when it pivots in response to an opening operation being performed on the exterior door handle,

wherein a linkage, which is coupled to a lower end of the transmission rod, is formed at the one end of the second lever,

a plane of rotation, which contains an arcuate trajectory traced by the linkage when it pivots in response to the opening operation being performed, is located farther in a frontward direction of the vehicle frame than the fixing surface and

the plane of rotation extends at an angle relative to a plane containing the fixing surface such that the plane of rotation intersects the plane of the fixing surface in a downward direction of the vehicle frame.

Other aspects and advantages of the present invention will be apparent from the embodiments disclosed in the following description and the attached drawings, the illustrations exemplified in the drawings, and the general concept or gist of the invention disclosed in the entire description and drawings.

FIG. 1 is a perspective view of a vehicle door lock apparatus according to a first embodiment of the present teachings.

FIG. 2 is a perspective view of the vehicle door lock apparatus.

FIG. 3 is a perspective view of a latch housing and a latch mechanism of the first embodiment.

FIG. 4 is an exploded perspective view of the latch housing and the latch mechanism.

FIG. 5 is a front view of a first housing and an actuating mechanism of the first embodiment.

FIG. 6 is an exploded perspective view of the first housing and the actuating mechanism.

FIG. 7 is a perspective view of the housing.

FIG. 8 is a perspective view of a second housing of the first embodiment.

FIG. 9 is an exploded perspective view of a worm wheel, an inside (“I/S”) lock lever, and a linearly moving lock lever of the first embodiment.

FIG. 10 is a front view of the first housing and the actuating mechanism.

FIG. 11 is a first schematic view for explaining the operations of an outside (“O/S”) open lever, an inertial lever, a fork, and a pawl of the first embodiment.

FIG. 12 is a second schematic view for explaining the operations of the O/S open lever, the inertial lever, the fork, and the pawl.

FIG. 13 is a third schematic view for explaining the operations of the O/S open lever, the inertial lever, the fork, and the pawl.

FIG. 14 is a fourth schematic view for explaining the operations of the O/S open lever, the inertial lever, the fork, and the pawl.

FIG. 15 is a schematic view for explaining a change in the positional relationships of the O/S open lever, the inertial lever, and the pawl relative to each other.

FIG. 16 is a schematic view for explaining the positional relationship of a door handle relative to a transmission rod in an embodiment in which the vehicle door lock apparatus of the first embodiment is mounted on, for example, a front door.

FIG. 17 is a schematic view for explaining the positional relationship of the door handle relative to the transmission rod in an embodiment in which the vehicle door lock apparatus of the first embodiment is mounted on, for example, a rear door.

Embodiments of the present teachings will be explained below with reference to the drawings.

First Embodiment

FIGS. 1 and 2 show a vehicle door lock apparatus 1 (hereinafter sometimes simply referred to as “door lock apparatus 1 ”) according to a representative, non-limiting first embodiment of the present teachings. As shown, e.g., in FIGS. 16 and 17 , the door lock apparatus 1 is configured to be affixed (attached) to a door (A 1 , A 2 ) that is openable and closable relative to a vehicle frame (chassis) of a vehicle, such as an automobile, a bus, a commercial vehicle, a truck, etc. By retaining (latching or holding) a striker that is affixed to the vehicle frame, the door lock apparatus 1 is capable of retaining (holding) the door closed with respect to the vehicle frame.

In FIGS. 1 and 2 , the door lock apparatus 1 is configured to be disposed on the inside at the rear end of the door provided on the left side surface of the vehicle frame. It is noted that, when another door lock apparatus 1 is affixed to the rear end of the door provided on the right side surface of the vehicle frame, the two door lock apparatuses 1 will be disposed in a mirror image state. In addition or in the alternative, the door lock apparatus 1 according to the present teachings can be provided in (on) a tail gate, or another portion of the vehicle.

The front-rear direction and the up-down direction shown in FIGS. 1 and 2 are based on the front-rear (longitudinal) direction and the up-down (vertical or height) direction of the vehicle. The vehicle inward-outward (lateral) direction shown in FIGS. 1 and 2 is based on a person sitting in the cabin of the vehicle. The left surface side of the vehicle is set as the vehicle exterior and the opposite side is set as the vehicle interior. The front-rear direction, the up-down direction, and the vehicle inward-outward direction shown in FIG. 3 and the reference directions shown in the subsequent Figures correspond to the reference directions shown in FIGS. 1 and 2 .

As shown in FIG. 1 , an exterior door handle H 1 and a key cylinder H 2 are disposed on the outer surface of a door (not shown in FIGS. 1 and 2 ; see FIGS. 16 and 17 for representative doors A 1 and A 2 ), to which the door lock apparatus 1 is affixed (attached). An interior door lock knob H 3 and an interior door handle H 4 are disposed on the inner (interior) surface of the door that is exposed to (faces) the cabin of the vehicle.

An upper end C 1 A of a transmission rod C 1 is operably coupled to the exterior door handle H 1 . The door lock apparatus 1 is disposed downward of the exterior door handle H 1 on the inside of the door (A 1 , A 2 ), as shown in FIGS. 16 and 17 . A lower end C 1 B of the transmission rod C 1 is operably coupled to a linkage 20 C of an outside (“O/S”) open lever 20 of the door lock apparatus 1 , as shown in FIGS. 1, 11-14, 16 and 17 .

The key cylinder H 2 is retained so as to be rotatable integrally with a key-cylinder retainer C 2 A, which is rotatably (turnably) provided at the upper end portion of the door lock apparatus 1 . As shown in FIG. 2 , the upper end of a link rod C 2 B is operably coupled to the key-cylinder retainer C 2 A. The lower end of the link rod C 2 B is connected via a link lever C 2 C to an outside (“O/S”) lock lever 30 , which will explained below with reference to FIG. 5 , etc.

As shown in FIG. 1 , a first end of a transmission cable C 3 is connected to the interior door lock knob H 3 . A first end of a transmission cable C 4 is connected to the interior door handle H 4 . As shown in FIG. 2 , a second end of the transmission cable C 3 is drawn into the door lock apparatus 1 and connected to an inside (“I/S”) lock lever 35 , which will be explained below with reference to FIG. 5 , etc. A second end of the transmission cable C 4 is drawn into the door lock apparatus 1 and connected to an inside (“I/S”) open lever 25 , which will also be explained below with reference to FIG. 5 , etc.

The door lock apparatus 1 includes a latch housing 9 , as shown in FIGS. 1-4 , and an actuating housing 7 , as shown in FIGS. 1, 2, and 5-8 . As shown in FIGS. 1 and 2 , the actuating housing 7 is assembled onto (joined to) the latch housing 9 .

As shown, e.g., in FIGS. 6-8 , the actuating housing 7 includes a first housing 70 and a second housing 80 , each made of resin. As shown in FIG. 7 , the first housing 70 includes a first peripheral edge section 73 surrounding a first base wall 71 . As shown in FIG. 8 , the second housing 80 includes a second peripheral edge section 83 surrounding a second base wall 81 . The second housing 80 is assembled onto (joined to) the first housing 70 by disposing the first base wall 71 opposite to the second base wall 81 and welding the first peripheral edge section 73 to the second peripheral edge section 83 , whereby a housing chamber 7 A is formed in the interior of the actuating housing 7 . An actuating mechanism 6 , as shown in FIGS. 5, 6, and 9-15 , is housed in the housing chamber 7 A.

As shown in FIG. 4 , the latch housing 9 includes a third housing 90 made of resin, as well as a base plate 99 and a back plate 98 , which are each made from steel plate. A fork pivot shaft 11 S and a pawl pivot shaft 12 S are inserted through the third housing 90 . The base plate 99 is disposed behind the third housing 90 . The back plate 98 is disposed in front of the third housing 90 . The rear end portions of the fork pivot shaft 11 S and the pawl pivot shaft 12 S are respectively crimped and thereby affixed to the base plate 99 . The front end portions of the fork pivot shaft 11 S and the pawl pivot shaft 12 S are respectively crimped and thereby affixed to the back plate 98 , whereby a latch chamber 9 A is formed in the interior of the latch housing 9 . A latch mechanism 8 , as shown in FIGS. 2, 4 , and 11 - 14 , is housed in the latch chamber 9 A.

As shown in FIGS. 5-7 , first and second supports 76 P and 76 Q are formed in (on) the first housing 70 . The first support 76 P projects from the first base wall 71 near a rear and upper end portion in the first peripheral edge section 73 of the first housing 70 . The second support 76 Q projects from the first base wall 71 near a rear and lower end portion in the first peripheral edge section 73 of the first housing 70 . The first and second supports 76 P and 76 Q each extend toward the second base wall 81 of the second housing 80 .

As shown in FIGS. 3 and 4 , first and second insertion-through holes 96 P and 96 Q are formed in the third housing 90 . The first insertion-through hole 96 P penetrates through the upper end of the third housing 90 in the vehicle inward-outward direction. The second insertion-through hole 96 Q penetrates through the lower end of the third housing 90 in the vehicle inward-outward direction.

As shown in FIG. 8 , first and second slip-off preventing parts 86 P and 86 Q are formed as recesses (holes) in the second housing 80 . The first slip-off preventing part 86 P is a recess (hole) formed near a rear and upper end of the second peripheral edge section 83 of the second housing 80 . The first slip-off preventing part 86 P is aligned with the distal end of the first support 76 P. The second slip-off preventing part 86 Q is a recess (hole) formed near a rear and lower end of the second peripheral edge section 83 of the second housing 80 . The second slip-off preventing part 86 Q is aligned with the distal end of the second support 76 Q.

Before the second housing 80 is assembled onto the first housing 70 , the third housing 90 is provisionally assembled (mounted) onto the first housing 70 . As shown, e.g., in FIG. 7 , the first housing 70 includes a groove-like guide 71 J formed in the rear end portion of the first base wall 71 . As shown in FIG. 4 , a rib 90 J protrudes from an upper end face of the third housing 90 towards the vehicle exterior. By moving the third housing 90 towards to the first housing 70 while guiding the rib 90 J into the guide 71 J, the third housing 90 can be provisionally assembled with the first housing 70 in the proper position (orientation).

As a result, the intermediate segment of the first support 76 P of the first housing 70 is inserted through the first insertion-through hole 96 P of the third housing 90 . Similarly, the intermediate segment of the second support 76 Q of the first housing 70 is inserted through the second insertion-through hole 96 Q of the third housing 90 .

Subsequently, when the second housing 80 is assembled (mounted) onto the first housing 70 , the distal end of the first support 76 P of the first housing 70 is fit into the first slip-off preventing part 86 P of the second housing 80 . The distal end of the second support 76 Q of the first housing 70 is fit into the second slip-off preventing part 86 Q of the second housing 80 . The first peripheral edge section 73 of the first housing 70 and the second peripheral edge section 83 of the second housing 80 are welded together, whereby the third housing 90 is joined to the first housing 70 and the second housing 80 .

As shown, e.g., in FIGS. 2 and 4 , the base plate 99 of the latch housing 9 has a fixing surface P 1 , and also includes a plurality of fixing holes 99 H and an entry opening 99 A formed in the base plate 99 . The fixing surface P 1 is formed on the surface that faces rearward of the base plate 99 . Although the surface facing rearward of the base plate 99 is uneven, the fixing surface P 1 is a flat surface designed to contact (abut) the rear end face of the door. Not-shown set screws are inserted through the rear end face of the door and are screwed into the fixing holes 99 H of the base plate 99 , whereby the door lock apparatus 1 is affixed to the door such that the fixing surface P 1 contacts (abuts against) the rear end face of the door and such that the entry opening 99 A is exposed at the rear end face of the door. When the door lock apparatus 1 moves in response to opening and closing of the door, the striker fixed to the vehicle frame respectively separates from or enters into the entry opening 99 A.

For example, in an embodiment in which the door lock apparatus 1 is mounted on a front door A 1 as shown in FIG. 16 , the fixing surface P 1 contacts the rear end face A 1 P of the front door A 1 . The rear end face A 1 P has a shape that corresponds to (is complementary to) the shape of the so-called “B pillar” of the vehicle frame that vertically extends between a front seat opening and a rear seat opening in the vehicle frame. The rear end face A 1 P is slightly inclined with respect to the vertical direction. Therefore, the fixing surface P 1 is also inclined at a small angle with respect to the vertical direction along the rear end face A 1 P.

In an alternate embodiment in which the door lock apparatus 1 is mounted on a rear door A 2 as shown in FIG. 17 , the fixing surface P 1 contacts the rear end face A 2 P of the rear door A 2 . The rear end face A 2 P has a shape that corresponds to (is complementary to) the shape of a rear tire housing of the vehicle frame. The rear end face A 2 P is inclined at a large angle with respect to the vertical direction. Therefore, the fixing surface P 1 is also inclined at a large angle with respect to the vertical direction along the rear end face A 2 P.

As shown in FIG. 4 , the latch mechanism 8 includes a fork 11 and a pawl 12 . The fork 11 is pivotably supported by a fork pivot shaft 11 S, which is disposed above the entry opening 99 A. A torsion coil spring 11 T is attached to the fork pivot shaft 11 S. The pawl 12 is pivotably supported by the pawl pivot shaft 12 S, which is disposed below the entry opening 99 A. The pawl pivot shaft 12 S defines a pawl axis X 12 that is at least substantially orthogonal to the fixing surface P 1 . A torsion coil spring 12 T is attached to the pawl pivot shaft 12 S.

As shown in FIGS. 11-14 , the fork 11 is urged (biased) by the torsion coil spring 11 T so as to pivot about the fork pivot shaft 11 S in the direction D 11 . The portion of the fork 11 that is located on the side of the entry opening 99 A has an inner convex segment 11 A and an outer convex segment 11 B. A striker S 1 , which is shown in FIG. 11 as having entered into the entry opening 99 A, fits in a cutout 11 C formed between the inner convex segment 11 A and the outer convex segment 11 B. In the state shown in FIG. 11 , the fork 11 retains the striker S 1 at the bottom of the entry opening 99 A. A latch surface 11 D configured to come into contact with a stopper surface 12 A, which will be explained below, is formed at (on) the distal end of the inner convex segment 11 A that faces the pawl 12 .

The pawl 12 is urged (biased) by the torsion coil spring 12 T so as to pivot about the pawl pivot shaft 12 S in the direction D 12 and holds the posture (orientation) shown in FIG. 11 .

The stopper surface 12 A is formed in (on) a portion of the pawl 12 that is directed towards the bottom of the entry opening 99 A in the orientation shown in FIG. 11 . The stopper surface 12 A is formed so as to face the latch surface 11 D. An arc forming the stopper surface 12 A is cut on the side that faces the fork 11 . A sliding surface 12 C that extends towards the pawl pivot shaft 12 S is formed starting from the part (location) where the arc is cut. A contacted portion 12 B is formed on the pawl 12 on the side that is opposite of the stopper surface 12 A across the pawl pivot shaft 12 S. As shown in FIG. 4 , the contacted portion 12 B projects forward and has a columnar shape. As shown in FIG. 3 , the front end of the contacted portion 12 B projects frontward from the latch chamber 9 A through the third housing 90 and enters the housing chamber 7 A.

Referring again to FIG. 11 , when the fork 11 retains (holds) the striker S 1 at the bottom of the entry opening 99 A, the stopper surface 12 A comes into contact with the latch surface 11 D of the inner convex segment 11 A, whereby the pawl 12 prevents the fork 11 from pivoting in the direction D 11 . The position of the fork 11 shown in FIG. 11 is the latch position that holds the striker S 1 in the entry opening 99 A.

As shown in FIG. 12 , when an inertial lever 29 , which will be explained below, comes into contact with the contacted portion 12 B of the pawl 12 and pushes the contacted portion 12 B up, the pawl 12 pivots about the pawl pivot shaft 12 S in the direction opposite of the direction D 12 by overcoming the urging force of the torsion coil spring 12 T. At this time, since the stopper surface 12 A separates from the latch surface 11 D, the pawl 12 no longer blocks the pivoting movement of the fork 11 . Therefore, the fork 11 pivots about the fork pivot shaft 11 S in the direction D 11 due to the urging force of the torsion coil spring 11 T so as to displace to the unlatch position, where the striker S 1 is permitted (released) to move out of (exit) the entry opening 99 A.

Conversely, when the striker S 1 enters the entry opening 99 A, the striker S 1 pushes against the outer convex segment 11 B, thereby causing the fork 11 to pivot in the direction opposite of the direction D 11 and to return from the unlatch position shown in FIG. 12 to the latch position shown in FIG. 11 . At this time, the distal end of the outer convex segment 11 B and then the distal end of the inner convex section 11 A sequentially come into slide-contact with the sliding surface 12 C. When the inner convex segment 11 A separates from the sliding surface 12 C, the pawl 12 pivots in the direction D 12 and returns to the original posture shown in FIG. 11 . Therefore, the stopper surface 12 A comes into contact with the latch surface 11 D and fixes the pivoting movement of the fork 11 in the latch position. As a result, the latch mechanism 8 holds the door closed with respect to the vehicle frame.

As shown in FIGS. 5, 6, 9, and 10 , the actuating mechanism 6 includes the O/S open lever 20 , the I/S open lever 25 , the inertial lever 29 , the O/S lock lever 30 , the I/S lock lever 35 , a linearly moving lock lever 40 , an electric motor M 1 , and a worm wheel 39 . The inertial lever 29 is a representative, non-limiting example of a “first lever” according to the present teachings. The O/S open lever 20 is a representative, non-limiting example of a “second lever” according to the present teachings.

As shown in FIGS. 6 and 7 , the first housing 70 includes an outside (“O/S”) open lever pivot shaft 20 S that projects rearward at (from) a rear and lower portion of the first base wall 71 . The O/S open lever pivot shaft 20 S defines a second axis X 20 . Although the latch housing 9 is not shown in FIG. 5 , the positions of the fixing surface P 1 and the pawl axis X 12 are shown relative to the actuating mechanism 6 . The second axis X 20 is inclined upward in the rearward direction and is inclined with respect to the pawl axis X 12 , which is at least substantially orthogonal to the fixing surface P 1 .

As shown in FIGS. 5 to 7 , a first shaft 75 P is formed in (on) a rear and lower part of the first base wall 71 of the first housing 70 . A second shaft 75 Q is formed in (on) a part of the first base wall 71 that is farther forward than the first shaft 75 P. A third shaft 75 R and a fourth shaft 75 S are formed in (on) a part located substantially in the center of the first base wall 71 . The first shaft 75 P, the second shaft 75 Q, the third shaft 75 R, and the fourth shaft 75 S respectively extend toward the second base wall 81 of the second housing 80 .

The O/S open lever 20 is pivotably supported by the O/S open lever pivot shaft 20 S. As shown in FIG. 6 , a torsion coil spring 20 T is attached to the O/S open lever pivot shaft 20 S. As shown in FIG. 11 , the O/S open lever 20 is urged (biased) by the torsion coil spring 20 T so as to pivot about the O/S open lever pivot shaft 20 S in the direction D 20 .

As shown in FIG. 7 , a fitting groove 24 is formed as a recess in the O/S open lever pivot shaft 20 S. As shown in FIG. 3 , a shaft receptacle 94 , in which a fitting plate 94 L is provided, is formed in the third housing 90 . Although not shown in the Figures, the fitting groove 24 of the O/S open lever pivot shaft 20 S fits with the fitting plate 94 L of the shaft receptacle 94 , whereby the O/S open lever 20 is prevented from slipping off from the O/S open lever pivot shaft 20 S.

As shown in FIGS. 1 and 11 , a first end of the O/S open lever 20 is located on the vehicle outward side and projects to the outside of the actuating housing 7 . The linkage (coupling part) 20 C is formed at the first end. An arcuate elongated hole 20 H penetrates through the linkage 20 C; the center of an imaginary circle, along which the arc extends, is located on the second axis X 20 . The lower end C 1 B of the transmission rod C 1 is bent rearward and coupled to the linkage 20 C by being inserted into the elongated hole 20 H with a resin clip C 1 C (shown in FIG. 1 ) securing it.

The lower end C 1 B of the transmission rod C 1 pushes the linkage 20 C downward in response to an opening operation being performed on the exterior door handle H 1 , whereby the linkage 20 C is displaced such that it traces an arcuate trajectory having its center on (at) the second axis X 20 . FIGS. 16 and 17 show a plane P 2 of rotation, which contains the arcuate trajectory traced by the linkage 20 C when it pivots in response to the opening operation being performed on the exterior door handle H 1 . The second axis X 20 is orthogonal to the plane P 2 of rotation. As shown in FIGS. 16 and 17 , the plane P 2 of rotation is located farther in the forward direction of the vehicle frame than the fixing surface P 1 . Furthermore, the plane P 2 of rotation extends at an angle relative to a plane containing the fixing surface P 1 such that the plane P 2 of rotation approaches (intersects) the plane of the fixing surface P 1 in the downward direction.

In this embodiment, an inclination angle α 1 of the plane P 2 of rotation with respect to the plane containing the fixing surface P 1 is 5° or more and 15° or less.

As shown in FIGS. 16 and 17 , the transmission rod C 1 may be formed such that it has a variety of bent shapes, in accordance with the particular application of the present teachings, as long as the lower end C 1 B extends in a direction that is at least substantially orthogonal to the plane P 2 of rotation and the lower end C 1 B is inserted into the elongated hole 20 H of the linkage 20 C, thereby adapting the door lock apparatus 1 to the particular shape of the door on which the door lock apparatus 1 is mounted. The direction that is at least substantially orthogonal to the plane P 2 of rotation is a direction that is at least substantially parallel to the second axis X 20 . For example, in FIG. 16 , the transmission rod C 1 extends vertically downward (or at least nearly vertically downward) from the upper end C 1 A. The lower end C 1 B of the transmission rod C 1 is bent at least substantially at a right angle and extends in a direction that is at least substantially orthogonal to the plane P 2 of rotation. In FIG. 17 , the transmission rod C 1 first extends vertically downward (or at least nearly vertically downward) from the upper end C 1 A, is then bent to be inclined slightly rearward and then is bent to be inclined slightly frontward, before being bent to extend substantially rearward at the lower end C 1 B. In particular, the transmission rod C 1 is bent above the linkage 20 C of the O/S open lever 20 and extends downward while being inclined slightly frontward so as to be generally parallel to the linkage 20 C. The lower end C 1 B of the transmission rod C 1 is bent substantially at a right angle and extends in a direction that is at least substantially orthogonal to the plane P 2 of rotation. It is noted that the design of the resin clip C 1 C shown in FIG. 1 is capable of securing a variety of shapes of transmission rods C 1 , although only two exemplary shapes thereof are shown in FIGS. 16 and 17 .

As shown in FIGS. 16 and 17 , the exterior door handle H 1 is pivotably supported about a handle axis XH 1 that typically extends at least substantially horizontally in the front-rear direction of the vehicle. Therefore, in general, a plane P 3 , which contains an arcuate trajectory traced by the upper end C 1 A of the transmission rod C 1 that is coupled to the exterior door handle H 1 when the upper end C 1 A pivots in response to the opening operation being performed on the exterior door handle H 1 , extends at least substantially in the vertical direction.

Referring again to FIG. 7 , a movement guide (displacement guide) 70 G is formed in the first base wall 71 of the first housing 70 . The movement guide 70 G is formed in a part of the first base wall 71 that is located on the vehicle outward side with respect to the O/S open lever pivot shaft 20 S and has an arcuate slit shape. The center of an imaginary circle, along which the arcuate slit extends, is located on (at) the second axis X 20 . In other words, the movement guide 70 G is formed as a recess (curved slot) that is contained within, or is at least substantially in parallel to, the plane P 2 of rotation shown in FIGS. 16 and 17 . As shown in FIG. 1 , the movement guide 70 G surrounds a portion of the O/S open lever 20 that is adjacent to the linkage 20 C and guides the pivoting movement of the O/S open lever 20 about the second axis X 20 .

As shown in FIGS. 5 and 6 , the inertial lever 29 is supported by the other end 20 B of the O/S open lever 20 so as to be pivotable about a first axis X 29 extending in the front-rear direction. As shown in FIG. 11 , a torsion coil spring 29 T (see FIG. 6 ) urges (biases) the inertial lever 29 so as to pivot about the first axis X 29 in the direction D 29 . As shown in FIGS. 5 and 15 , the first axis X 29 is at least substantially parallel to the pawl axis X 12 . The second axis X 20 is inclined with respect to the first axis X 29 .

When the exterior door handle H 1 is operated (e.g., manually pulled) to open the door and the transmission rod C 1 has moved downward as shown in FIG. 12 , the linkage 20 C of the O/S open lever 20 is pushed down too. The O/S open lever 20 pivots in the direction opposite of the direction D 20 , thereby raising the inertial lever 29 . The inertial lever 29 is displaced from the position indicated by a solid line in FIG. 15 to the position indicated by an alternating long dash and two short dashes line in FIG. 15 . That is, the inertial lever 29 rises while being inclined upward and frontward according to the inclination of the second axis X 20 with respect to the pawl axis X 12 . At this time, the upper end surface of the inertial lever 29 is maintained in a state of being at least substantially parallel to the lower end surface of the pawl 12 . Since the first axis X 29 is at least substantially parallel to the pawl axis X 12 , even when the inertial lever 29 pivots about the first axis X 29 to the position indicated by the alternating long dash and two short dashes line in FIG. 15 , the upper end surface of the inertial lever 29 is maintained in a state of being at least substantially parallel to the lower end surface of the pawl 12 .

As shown in FIGS. 5 and 6 , the I/S open lever 25 is pivotably supported by the first shaft 75 P. The second end of the transmission cable C 4 (see FIGS. 1 and 2 ) is operably coupled to one end 25 A of the I/S open lever 25 that is spaced downward from the first shaft 75 P. That is, the I/S open lever 25 is operably coupled to the interior door handle H 4 via the transmission cable C 4 .

As shown in FIGS. 5 and 6 , an operating part 25 B is formed on a part above the one end 25 A of the I/S open lever 25 . The I/S open lever 25 pivots counterclockwise when the interior door handle H 4 is operated (e.g., manually pulled) to open the door. Consequently, the operating part 25 B pushes the other end 20 B of the O/S open lever 20 up and raises the inertial lever 29 .

As shown in FIG. 5 , a lower surface 20 E on the other end 20 B of the O/S open lever 20 is designed to contact the operating part 25 B; the lower surface 20 E extends at least substantially parallel to the second axis X 20 in the front-rear direction and is inclined slightly downward. Consequently, the force imparted by the operating part 25 B to push up the other end portion 20 B of the O/S open lever 20 is reliably transmitted to the O/S open lever 20 .

As shown in FIGS. 6 and 7 , the first housing 70 also includes an outside (“O/S”) lock lever pivot shaft 30 S that projects from an upward portion of the first base wall 71 toward the vehicle interior.

As shown in FIGS. 5 and 6 , the O/S lock lever 30 is pivotably supported by the O/S lock lever pivot shaft 30 S. An engaging concave segment 30 D is formed as a recess in the O/S lock lever 30 and bends in the radial inward direction. The O/S lock lever 30 includes a coupling shaft 30 J that projects toward the vehicle interior. As shown in FIG. 2 , the coupling shaft 30 J projects outward of the second housing 80 . The link lever C 2 C is fixed to the distal end portion of the coupling shaft 30 J so as to be integrally rotatable therewith.

Referring to FIG. 5 , the O/S lock lever 30 pivots counterclockwise in response to a locking operation being performed on the key cylinder H 2 . On the other hand, the O/S lock lever 30 pivots clockwise in response to an unlocking operation being performed on the key cylinder H 2 .

As shown in FIGS. 5 and 6 , the I/S lock lever 35 is pivotably supported by the second shaft 75 Q. The second end of the transmission cable C 3 (shown in FIGS. 1 and 2 ) is coupled to one end 35 A of the I/S lock lever 35 . That is, the I/S lock lever 35 is operably coupled to the interior door lock knob H 3 via the transmission cable C 3 . The I/S lock lever 35 pivots from the position shown in FIG. 5 to the position shown in FIG. 10 in response to a locking operation being performed on the interior door lock knob H 3 . The I/S lock lever 35 pivots from the position shown in FIG. 10 to the position shown in FIG. 5 in response to an unlocking operation being performed on the interior door lock knob H 3 .

As shown in FIGS. 5 and 6 , a cam 35 C is formed in an upper part of the I/S lock lever 35 . As shown in FIG. 9 , an operating part 35 B projects toward the vehicle exterior from the surface of the I/S lock lever 35 that faces the vehicle exterior.

As shown in FIGS. 5 and 6 , the worm wheel 39 is rotatably (turnably) supported by the third shaft 75 R. As shown in FIG. 9 , a cam section 39 C configured to engage with the cam 35 C of the I/S lock lever 35 is formed on the surface of the worm wheel 39 that faces the vehicle exterior. When the electric motor M 1 is actuated in response to a locking operation or a unlocking operation requested by a remote control key or the like, the worm wheel 39 is driven by the electric motor M 1 to rotate and thereby turns (pivots) clockwise or counterclockwise. Due to the engagement of the cam section 39 C and the cam 35 C, the worm wheel 39 causes the I/S lock lever 35 to pivot between the position shown in FIG. 5 and the position shown in FIG. 10 .

As shown in FIGS. 5 and 6 , the fourth shaft 75 S is inserted through an elongated hole 40 H that extends in the up-down direction, whereby the linearly moving lock lever 40 is supported by the fourth shaft 75 S so as to be linearly movable. The fourth shaft 75 S has a substantial “C” shaped cross-section. The linearly moving lock lever 40 has a substantial “Y” shape that forks above the elongated hole 40 H.

As shown in FIGS. 6 and 9 , a linearly moving convex segment 40 E projects toward the vehicle exterior from a part of the linearly moving lock lever 40 that branches rearward and upward. As shown in FIG. 7 , a linear-movement guide groove 71 E extends in the up-down direction at a location that is upward and rearward relative to the fourth shaft section 75 S; the linear-movement guide groove 71 E is formed as recess in the first base wall 71 of the first housing 70 . The linearly moving convex segment 40 E is guided by the linear-movement guide groove 71 E, whereby the linearly moving lock lever 40 is capable of linearly moving in the up-down direction without inclining (tilting).

As shown in FIGS. 5 and 6 , a concave recess 40 B is formed in the lower end portion of the linearly moving lock lever 40 . As shown in FIG. 5 , the operating part 35 B of the I/S lock lever 35 engages in the concave recess 40 B.

As shown in FIG. 9 , an engaging convex part 40 C projects toward the vehicle exterior at the distal end of a part of the linearly moving lock lever 40 that branches forward and upward. As shown in FIGS. 5 and 10 , the engaging convex part 40 C projects into the engaging concave segment 30 D of the O/S lock lever 30 .

When the I/S lock lever 35 pivots from the position shown in FIG. 5 to the position shown in FIG. 10 in response to a locking operation being performed on the interior door lock knob H 3 or a locking operation requested by the remote control key or the like, the displacement of the I/S lock lever 35 is transmitted to the linearly moving lock lever 40 via the concave recess 40 B and the operating part 35 B. As a result thereof, the linearly moving lock lever 40 is pushed up from the position shown in FIG. 5 to the position shown in FIG. 10 .

When the I/S lock lever 35 pivots from the position shown in FIG. 10 to the position shown in FIG. 5 in response to an unlocking operation being performed on the interior door lock knob H 3 or an unlocking operation requested by the remote control key or the like, the displacement of the I/S lock lever 35 is transmitted to the linearly moving lock lever 40 via the concave recess 40 B and the operating part 35 B. As a result thereof, the linearly moving lock lever 40 is pulled down from the position shown in FIG. 10 to the position shown in FIG. 5 .

When the O/S lock lever 30 pivots counterclockwise in response to the locking operation being performed on the key cylinder H 2 , the displacement of the O/S lock lever 30 is transmitted to the linearly moving lock lever 40 via the engaging concave segment 30 D and the engaging convex part 40 C. As a result thereof, the linearly moving lock lever 40 is lifted (pulled up) from the position shown in FIG. 5 to the position shown in FIG. 10 .

When the O/S lock lever 30 pivots clockwise in response to the unlocking operation being performed on the key cylinder H 2 , the displacement of the O/S lock lever 30 is transmitted to the linearly moving lock lever 40 via the engaging concave segment 30 D and the engaging convex part 40 C. As a result thereof, the linearly moving lock lever 40 is pushed down from the position shown in FIG. 10 to the position shown in FIG. 5 .

As shown in FIGS. 9 and 11-14 , a first surface 44 A, a second surface 44 B, and a third surface 44 C are formed on the linearly moving lock lever 40 between the elongated hole 40 H and the concave recess 40 B. The first surface 44 A, the second surface 44 B, and the third surface 44 C are formed on the surface of the linearly moving lock lever 40 that faces the vehicle exterior. The first surface 44 A and the third surface 44 C are each flat surfaces that extend in the up-down direction. The first surface 44 A is displaced (shifted) more towards the vehicle interior than the third surface 44 C. The second surface 44 B is an inclined surface that connects the lower end of the first surface 44 A with the upper end of the third surface 44 C.

As shown in FIGS. 5, 6, and 11-14 , a projection 29 A projects forward from the front surface of the inertial lever 29 . The projection 29 A comes into slide-contact with the first surface 44 A, the second surface 44 B, and the third surface 44 C in response to the linear movement of the linearly moving lock lever 40 .

As shown in FIGS. 3 and 11-14 , an inertial lever guide surface 90 G is formed on the third housing 90 on the side of the housing chamber 7 A. The inertial lever guide surface 90 G is a downward flat surface located farther towards the vehicle exterior than the contacted portion 12 B of the pawl 12 . The inertial lever guide surface 90 G extends toward the vehicle exterior so as to separate (be spaced) from the contacted portion 12 B. As shown in FIG. 11 , when the O/S open lever 20 has not yet been pivoted, the inertial lever guide surface 90 G is located between the lower end of the contacted portion 12 B and the upper end of the inertial lever 29 in the up-down direction.

The position of the linearly moving lock lever 40 shown in FIGS. 11 and 12 is the same as the position of the linearly moving lock lever 40 shown in FIG. 5 . The position of the linearly moving lock lever 40 shown in FIGS. 13 and 14 is the same as the position of the linearly moving lock lever 40 shown in FIG. 10 .

When the linearly moving lock lever 40 is located at the position shown in FIGS. 11 and 12 , the projection 29 A of the inertial lever 29 comes into contact with the first surface 44 A of the linearly moving lock lever 40 , whereby the inertial lever 29 is retained in an upward position. In the state shown in FIG. 12 , if the inertial lever 29 rises, the inertial lever 29 comes into contact with the contacted portion 12 B and causes the pawl 12 to open the fork 11 so that the striker S 1 can be released.

When the linearly moving lock lever 40 is displaced to the position shown in FIGS. 10, 13, and 14 , the projection 29 A of the inertial lever 29 comes into slide-contact with the second surface 44 B of the linearly moving lock lever 40 and then comes into contact with the third surface 44 C, whereby the inertial lever 29 is held inclined toward the vehicle exterior. In the state shown in FIG. 14 , if the inertial lever 29 rises, the inertial lever 29 comes into contact with the inertial lever guide surface 90 G, the inertial lever 29 separates from the contacted portion 12 B, and the pawl 12 continues to fix (retain) the fork 11 .

The position of the inertial lever 29 shown in FIGS. 11 and 12 is an unlock position where the inertial lever 29 is capable of acting on the pawl 12 . The position of the inertial lever 29 shown in FIGS. 13 and 14 is a lock position where the inertial lever 29 is incapable of acting on the pawl 12 . In the position shown in FIGS. 10, 13, and 14 , the third surface 44 C comes into contact with the projection 29 A and the linearly moving lock lever 40 retains the inertial lever 29 in the lock position. The position of the linearly moving lock lever 40 shown in FIGS. 10, 13, and 14 is a locked position.

In the position shown in FIGS. 5, 11, and 12 , the third surface 44 C separates (is spaced) from the projection 29 and the linearly moving lock lever 40 does not hold the inertial lever 29 in the lock position shown in FIGS. 13 and 14 . The inertial lever 29 brings the projection 29 A into contact with the first surface 44 A due to the urging force of the torsion coil spring 29 T. When an impact (shock or impulse) acts on the inertial lever 29 , the inertial lever 29 causes the projection 29 A to separate from the first surface 44 A and is displaced to the lock position. The position of the linearly moving lock lever 40 shown in FIGS. 5, 11, and 12 is an unlocked position.

In the unlocked position shown in FIGS. 5, 11, and 12 , the linearly moving lock lever 40 causes the inertial lever 29 to stand upright and enables the fork 11 located in the latch position shown in FIG. 11 to be displaced to the unlatch position shown in FIG. 12 . In the locked position shown in FIGS. 10, 13 , and 14 , the linearly moving lock lever 40 inclines the inertial lever 29 and disables the fork 11 located in the latch position shown in FIG. 11 from being displaced to the unlatch position shown in FIG. 12 .

The above-described representative door lock apparatus 1 , which has such a configuration, can hold the door closed with respect to the vehicle frame, open the door, and lock or unlock the door in the closed state in response to different types of operations performed by an occupant of the vehicle.

Operation and Effects

In the door lock apparatus 1 of the above-described embodiment, the plane P 2 of rotation, which contains the arcuate trajectory traced by the linkage 20 C of the O/S open lever 20 when the linkage 20 C pivots in response to the opening operation being performed on the exterior door handle H 1 , is located farther in the frontward direction of the vehicle frame than the fixing surface P 1 . Furthermore, the plane P 2 of rotation extends at an angle relative to a plane containing the fixing surface P 1 such that the plane P 2 of rotation intersects the plane of the fixing surface P 1 in a downward direction of the vehicle frame, e.g., as shown in FIGS. 16 and 17 .

Therefore, even if the door lock apparatus 1 is mounted on the door with the fixing surface P 1 of the base plate 99 inclined with respect to the vertical direction due to the shape of the door on which the vehicle door lock apparatus 1 is mounted, it is possible to reduce the inclination of the plane P 2 of rotation, which contains the trajectory of the linkage 20 C, relative to the plane P 3 , which contains the arcuate trajectory traced by the upper end C 1 A of the transmission rod C 1 when the upper end C 1 A pivots in response to the opening operation being performed on the exterior door handle H 1 .

More specifically, in an embodiment in which the door lock apparatus 1 is mounted on the front door A 1 , e.g., as shown in FIG. 16 , the plane P 2 of rotation, which contains the trajectory (movement path) of the linkage 20 C, extends in a substantially vertical direction and is at least substantially parallel to the plane P 3 , which contains the trajectory (movement path) of the upper end C 1 A of the transmission rod C 1 . In another embodiment in which the door lock apparatus 1 is instead mounted on the rear door A 2 , e.g., as shown in FIG. 17 , the plane P 2 of rotation, which contains the trajectory (movement path) of the linkage 20 C, is slightly inclined relative to the vertical direction. Therefore, the inclination relative to the plane P 3 , which contains the trajectory (movement path) of the upper end C 1 A of the transmission rod C 1 , decreases.

In particular, in the door lock apparatus 1 of the above-described embodiment, since the inclination angle α 1 of the plane P 2 of rotation with respect to the plane of the fixing surface P 1 is 5° or more and 15° or less, it is possible to reliably reduce the angle of inclination of the plane P 2 of rotation with respect to the plane P 3 even when the door lock apparatus 1 is mounted on doors having differing shapes.

As a result, in the door lock apparatus 1 of the above-described embodiment, the transmission rod C 1 is less likely to be distorted when the opening operation is being performed on the exterior door handle H 1 . Consequently, it is possible to inhibit or prevent a deterioration in operation sensitivity, a loss of transmission stroke, etc.

Therefore, with the door lock apparatus 1 of the above-described embodiment, it is possible to satisfactorily transmit the opening operation from the exterior door handle H 1 to the O/S open lever 20 via the transmission rod C 1 . Consequently, it is possible to open any door, such as the front door A 1 , the rear door A 2 , etc., in a satisfactory manner.

In addition, the door lock apparatus 1 of the present teachings may be mounted on a variety of types of door shapes, e.g., as shown in FIGS. 16 and 17 , by preparing a plurality of transmission rods having a plurality of different bent shapes, as the transmission rod C 1 , as long as the lower end C 1 B extends in a direction that is at least substantially orthogonal to the plane P 2 of rotation and the lower end C 1 B is inserted into the elongated hole 20 H of the linkage 20 C. In this way, because the lower end C 1 B of the transmission rod C 1 is coupled to the linkage 20 C in a direction that is at least substantially orthogonal to the plane P 2 of rotation, the transmission of the opening operation from the lower end C 1 B of the transmission rod C 1 to the linkage 20 C of the O/S open lever 20 can be performed in a more ideal manner.

Furthermore, the door lock apparatus 1 of the present teachings may include the movement guide 70 G formed in the first base wall 71 of the first housing 70 , e.g., as shown in FIGS. 1 and 7 . In such an embodiment, the movement guide 70 G surrounds a portion of the O/S open lever 20 that is adjacent to the linkage 20 C in a direction that is at least substantially orthogonal to the plane P 2 of rotation, e.g., in the direction of the second axis X 20 . By utilizing the movement guide 70 G, it is possible to inhibit or reduce rattling during the pivoting movement of the O/S open lever 20 . During assembly, the O/S open lever 20 can be provisionally fixed by inserting a portion of the O/S open lever 20 that is adjacent to the linkage 20 C into the movement guide 70 G. Therefore, it is possible to easily assembly (mount) the third housing 90 onto the first housing 70 and to easily assembly (mount) the second housing 80 onto the first housing 70 .

In addition, the door lock apparatus 1 of the present teachings may include the inertial lever 29 that is supported by the O/S open lever 20 so as to be pivotable about the first axis X 29 , which is at least substantially parallel to the pawl axis X 12 , e.g., as shown in FIGS. 5 and 15 . In such an embodiment, when the inertial lever 29 rises and acts on (pushes) the pawl 12 as indicated by the alternating long dash and two short dashes line in FIG. 15 , it is possible to reduce or minimize the influence of the inclination of the second axis X 20 on the pawl axis X 12 , i.e. the influence of the inclination of the plane P 2 of rotation with respect to the fixing surface P 1 . Even if the inertial lever 29 pivots about the first axis X 29 at the position indicated by the alternating long dash and two short dashes line in FIG. 15 , the upper end surface of the inertial lever 29 is maintained in the state in which it is at least substantially parallel to the lower end surface of the pawl 12 . Therefore, the inertial lever 29 makes it possible for the pawl 12 to release the fork 11 more satisfactorily.

Although the present invention has been described above in line with a detailed embodiment, it is needless to say that the invention is not limited to the above-described detailed embodiment, and it may be appropriately modified in application without departing from the gist of the invention.

For example, in the above-described first embodiment, the inertial lever 29 , which is a representative, non-limiting example of a first lever, is pivotably supported by the O/S open lever, which is a representative, non-limiting example of a second lever. However, the present invention is not limited to this configuration. For example, a transmission lever or the like may be interposed between the first lever and the second lever. A specific example of such a modified embodiment is explained below. Instead of the elongated hole 20 H according to the above-described first embodiment, a round hole may penetrate through the linkage of the second lever. In this case, the lower end of the transmission rod is coupled to the round hole. Consequently, the second lever will always pivot when the opening operation is being performed on the exterior door handle. Furthermore, the transmission lever may be pivotably supported independently from the second lever. In this case, when the second lever pivots in response to the opening operation being performed on the exterior door handle, the second lever comes into contact with the transmission lever and causes the transmission lever to pivot and displace (move) the first lever. Thus, when the opening operation is being performed on the interior door handle, the transmission lever pivots independently from the second lever and displaces the first lever. Such a configuration is also included within the scope of the present teachings.

Representative, non-limiting examples of the present invention were described above in detail with reference to the attached drawings. This detailed description is merely intended to teach a person of skill in the art further details for practicing preferred aspects of the present teachings and is not intended to limit the scope of the invention. Furthermore, each of the additional features and teachings disclosed above may be utilized separately or in conjunction with other features and teachings to provide improved vehicle door lock apparatuses and methods for manufacturing and operating the same.

Moreover, combinations of features and steps disclosed in the above detail description may not be necessary to practice the invention in the broadest sense, and are instead taught merely to particularly describe representative examples of the invention. Furthermore, various features of the above-described representative examples, as well as the various independent and dependent claims below, may be combined in ways that are not specifically and explicitly enumerated in order to provide additional useful embodiments of the present teachings.

All features disclosed in the description and/or the claims are intended to be disclosed separately and independently from each other for the purpose of original written disclosure, as well as for the purpose of restricting the claimed subject matter, independent of the compositions of the features in the embodiments and/or the claims. In addition, all value ranges or indications of groups of entities are intended to disclose every possible intermediate value or intermediate entity for the purpose of original written disclosure, as well as for the purpose of restricting the claimed subject matter.