SMART LATCH ASSEMBLY WITH ACTUATOR MODULE

A closure latch assembly, comprising a latch module including a mechanism operable in a first state and in a second state, an actuator module including a power actuator for shifting the mechanism from its first state into its second state, and a control unit for controlling actuation of the power actuator, and an attachment arrangement for securing the actuator module to the latch module.

FIELD

The present disclosure relates to generally to power-operated closure latch assemblies of the type used in closure systems for releaseably latching a closure panel to a body portion of a motor vehicle. More particularly, the present disclosure is directed to a closure latch assembly having a standardized actuator module capable of being attached to a plurality of different latch modules and which is configured to include an ECU/actuator assembly and an ECU cover.

BACKGROUND

This section provides background information which is not necessarily prior art to the inventive concepts embodied in the present disclosure.

Continued increases in technology, driven by consumer demand for advanced comfort and convenience features, has resulted in more electronics being integrated in modern motor vehicles. To this end, electronic controllers and electronically-controlled devices are now used to control a wide variety of functions in the vehicle. For example, many modern vehicles are now equipped with a passive (i.e. “keyless”) entry system to permit locking/unlocking and release of closure panels (i.e. doors, tailgates, liftgates, decklids, etc.) without the use of a traditional key-type entry system. In this regard, some popular functions now available with such passive entry systems include power lock/unlock, power cinch, and power release. Thus “powered” functions are provided by a closure latch assembly mounted to the closure panel and which is equipped with a latch module having a ratchet/pawl type of latch mechanism that is selectively actuated via actuation of at least one electric actuator. A latch control unit is electronically connected to the electric actuator for controlling actuation of the electric actuator.

Movement of the closure panel from an open position toward a closed position results in a striker (mounted to a structural portion of the vehicle) engaging and forcibly rotating the ratchet, in opposition to a biasing force normally applied to the ratchet via a ratchet biasing member, from a striker release position toward a striker capture position. Once the ratchet is located in its striker capture position, the pawl moves, due to the urging of a pawl biasing member, into a ratchet holding position whereat the pawl mechanically engages and holds the ratchet in its striker capture position, thereby latching the latch mechanism and holding the closure panel in its closed position. A latch release mechanism is commonly associated with the latch module for causing movement of the pawl from its ratchet holding position into a ratchet releasing position whereat the pawl is disengaged from the ratchet. Thereafter, the ratchet biasing member drives the ratchet back to its striker release position, thereby releasing the latch mechanism and permitting movement of the closure panel to its open position.

Closure latch assemblies providing a power release feature typically have the electric “power release” actuator configured to actuate the latch release mechanism for releasing the latch mechanism. The electric power release actuator is part of the latch module and is controlled via the latch control unit in response to a latch release signal generated by the passive entry system (i.e. via a key fob or a handle-mounted switch). In many instances, the latch control unit is part of an electronic controller unit (ECU) module. Conventionally, the ECU module has been located remotely from the closure latch assembly and is electrically connected to the electric power release actuator via a wiring harness. More recently, closure latch assemblies have been developed with the ECU module mounted directly to the latch module to provide an integrated configuration which permits elimination of the wiring harness.

Typically, the ECU module includes at least one circuit board, such as a printed circuit board (PCB), configured to supply electrical power to, and control operation of, the power actuator based on the control circuits and electrical components on the circuit board. In addition, the ECU module may include backup power devices (i.e. capacitors, super capacitors, backup batteries, etc.) which are also mounted to the circuit board and function to provide electrical power in the event of a loss of power from the vehicle's battery. These backup power devices are much larger, in terms of mass and size, than the other electrical components mounted to the circuit board. Since the circuit board(s), electrical components and backup power devices are sensitive to environmental damage, the ECU module typically includes a protective, fluid-tight enclosure assembly to prevent the ingress of dirt and moisture.

Another issue with conventional ECU modules, especially those mounted to a moveable closure panel, is that the electrical components and backup power devices are subjected to high deceleration forces when the closure panel reaches its end of travel (i.e. open and fully-closed) positions. These deceleration forces can be significant and can potentially cause the electrical components and/or the backup power devices to be jarred and eventually damages or detached from the circuit board. Accordingly, the enclosure assembly also is designed to absorb or otherwise dampen these deceleration forces.

While closure latch assemblies having an integrated configuration for the latch module and ECU module provide size and packaging advantages, the need to develop a specific or “dedicated” ECU module configured to mate with each latch module adds complexity and cost. To this end, it would be desirable to develop a standardized or “stand-alone” ECU module having an enclosure assembly adapted to be attached to different latch modules so as to provide interchangeable configurations. In addition to the logistical advantages of having a standardized ECU module capable of being used with different latch modules or different versions of the same latch module, the ECU module could be tested, calibrated and/or debugged independently of the latch module.

In view of the above, there is a recognized need to develop a stand-alone ECU module that is configured to protect the electrical components and backup power devices against damage from exposure to environmental elements and high deceleration forces, that is cost effective to develop and manufacture, and that can be easily adapted to a variety of different latch modules. Moreover, while current power-operated closure latch assemblies are sufficient to meet all regulatory requirements and provide the desired consumer expectations for enhanced comfort and convenience, a need exists directed toward advancing the technology and providing alternative power-operated closure latch assemblies that address and overcome at least some of the known shortcomings associated with conventional arrangements.

SUMMARY

This section provides a general summary of various aspects, features and structural embodiments provided by or associated with the inventive concepts hereinafter disclosed in accordance with the present disclosure and is not intended to be a comprehensive summation and/or limit the interpretation and scope of protection afforded by the claims.

In an aspect, this disclosure provides a closure latch assembly including a latch module and an actuator module configured to be mounted with and secured to the latch module.

In a related aspect, the actuator module is a stand-alone standardized device configured to be directly secured to a plurality of different latch modules.

In another aspect, the actuator module includes a power actuator operable for actuating a mechanism associated with the latch module to provide a “powered” function, and an ECU controlling actuation of the power actuator.

In accordance with these and other aspects, the closure latch assembly of the present disclosure includes a latch module including a mechanism operable in a first state and in a second state; an actuator module including a power actuator for shifting the mechanism from its first state into its second state, and a control unit for controlling actuation of the power actuator; and an attachment arrangement for securing the actuator module to the latch module.

In a related aspect, the actuator module includes a housing plate having a first side facing the latch module and an opposite second side, and having a port extending from the first side to the opposite second side, and the power actuator includes an electric motor provided on the opposite second side, the electric motor having a motor shaft extending through the port.

The actuator module associated with the closure latch assembly of the present disclosure includes an ECU/actuator assembly and an ECU cover. The ECU/actuator assembly includes a housing plate, and the control unit is mounted to and at least partially over-molded on the housing plate. The control unit includes a printed circuit board (PCB) having at least one of an electrical connector and a backup power device, and the control unit and the power actuator are part of a common assembly. The power actuator includes a carrier plate secured to housing plate, an electric motor secured to the carrier plate and driving a drive pinion, a drive gear rotatably mounted to the carrier plate and meshed with the drive pinion, and a gear stop bumper secured to the carrier plate. The drive gear includes an actuation feature operatively connected to the mechanism within the latch module such that rotation of the drive gear from the first position to a second position via energization of the electric motor results in shifting of the mechanism from its first state into its second state.

In accordance with these and other aspects, the present disclosure is directed to a method of manufacturing an actuator module including a power actuator for shifting states of a latch module including a mechanism operable in a first state and in a second state, the power actuator including a carrier plate, an electric motor securable to the carrier plate and comprising a motor shaft driving a drive pinion, and a drive gear rotatably mounted to the carrier plate and meshed with the drive pinion, the method comprising the steps of: overmolding the carrier plate to a housing plate comprising a first side and a second side; forming a port in the housing plate for receiving the motor shaft therethrough extending from the first side to the second side; sealing the port; securing the electric motor to the carrier plate on the first side of the housing plate; positioning a control unit for controlling actuation of the power actuator on the first side of the housing plate; and connecting the control unit to the electric motor.

In accordance with these and other aspects, the actuator module of the present disclosure includes an ECU/actuator assembly, an ECU cover, and an attachment arrangement for attaching the ECU cover to the ECU/actuator assembly and for attaching the actuation module to the latch module. The ECU/actuator assembly is generally configured to include a housing plate and a control unit mounted to and at least partially overmolded on the housing plate. The control unit is generally configured to include a printed circuit board having electrical contacts and at least one backup power source mounted thereon, and a power actuator. The power actuator includes a carrier plate adapted to be secured to the housing plate, an electric motor secured to the carrier plate and having a motor shaft driving a drive pinion, a drive gear rotatably mounted to the carrier plate and in constant mesh with the drive pinion, an actuation feature extending from the drive gear and configured to interact with a latch mechanism of the latch module, and a gear stop bumper mounted to the carrier plate. The axis of rotation of the motor shaft being generally aligned in parallel with a pivotable member of the latch mechanism.

In accordance with yet another aspect, there is provided a closure latch assembly, including a latch module including a mechanism operable in a first state and in a second state, and an actuator module including a housing plate comprising a first side facing the latch module and an opposite second side, and a port extending from the first side through to the opposite second side, a power actuator provided on the opposite second side and comprising a motor shaft extending through the port, the power actuator for shifting the mechanism from its first state into its second state, and a control unit provided on the opposite second side for controlling actuation of the power actuator.

These and other aspects and areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are solely intended for purpose of illustration and are not intended to limit the scope of the present disclosure. The drawings that accompany the detailed description are described below.

Corresponding reference numbers are used to indicate corresponding components throughout the several views associated with the above-identified drawings;

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference to the accompanying drawings. To this end, the example embodiments are provided so that this disclosure will be thorough, and will fully convey its intended scope to those who are skilled in the art. Accordingly, numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. However, it will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms, and that neither should be construed to limit the scope of the present disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

In the following detailed description, the expression “closure latch assembly” will be used to generally, as an illustrative example, indicate any power-operated latch device adapted for use with a vehicle closure panel to provide a “powered” (i.e. release, cinch, lock/unlock, etc.) feature. Additionally, the expression “closure panel” will be used to indicate any element moveable between an open position and at least one closed position, respectively opening and closing an access to an inner compartment of a motor vehicle and therefore includes, without limitations, decklids, tailgates, liftgates, bonnet lids, and sunroofs in addition to the sliding or pivoting side passenger doors of a motor vehicle to which the following description will make explicit reference, purely by way of example.

Referring initially toFIG. 1of the drawings, a motor vehicle10is shown to include a vehicle body12defining an opening14to an interior passenger compartment. A closure panel16is pivotably mounted to vehicle body12for movement between an open position (shown), a partially-closed position, and a fully-closed position relative to opening14. A closure latch assembly18is rigidly secured to closure panel16adjacent to an edge portion16A thereof and is releasably engageable with a striker20that is fixedly secured to a recessed edge portion14A of vehicle body12forming a portion of opening14. As will be detailed, closure latch assembly18is generally comprised of a latch module22, an actuator module24, and an attachment arrangement26connecting actuator module24to latch module22and providing a sealed interface therebetween. Latch module includes a latch mechanism32(FIGS. 6 and 7) operable to engage striker20and releaseably hold closure panel16in one of its partially-closed and fully-closed positions. An outside handle21and an inside handle23are provided for actuating (i.e. mechanically and/or electrically) closure latch assembly18to release striker20and permit subsequent movement of closure panel16to its open position. An optional lock knob25is shown which provides a visual indication of the locked state of closure latch assembly18and which may also be operable to mechanically change the locked state of closure latch assembly18. A weather seal28is mounted on edge portion14A of opening14in vehicle body12and is adapted to be resiliently compressed upon engagement with a mating sealing surface on closure panel16when closure panel16is held by closure latch assembly18in its fully-closed position so as to provide a sealed interface therebetween which is configured to prevent entry of rain and dirt into the passenger compartment while minimizing audible wind noise. For purpose of clarity and functional association with motor vehicle10, the closure panel is hereinafter referred to as door16.FIGS. 2 through 5illustrate various views of closure latch assembly18prior to installation in door16and show the general orientation of actuator module24relative to latch module22.

Referring now toFIG. 6, a diagrammatical version of closure latch assembly18illustrates the general orientation of latch module22, actuator module24, and attachment arrangement26. Latch module22generally includes a latch housing30within which the components of latch mechanism32and a latch release mechanism33are supported. For purposes of illustration only, a non-limiting version of latch mechanism32is shown inFIGS. 7A-7D, generally include a latch frame plate34, ratchet36, and a pawl38having a roller-type engagement device40, by way of example and without limitation, such as disclosed in US Publication No. 2019/0242163, filed under U.S. application Ser. No. 16/268,603 on Feb. 16, 2019, owned by Applicant herein, which is incorporated herein by way of reference in its entirety. Ratchet36is supported on latch frame plate34by a ratchet pivot post42for movement between a released or “striker release” position (FIG. 7B), a soft close or “secondary striker capture” position (FIG. 7C), and a hard close or “primary striker capture” position (FIGS. 7A and 7D). Ratchet36includes a striker guide channel44terminating in a striker retention cavity46. As seen, latch frame plate34includes a fishmouth slot48aligned to accept movement of striker20relative thereto upon movement of door16toward its closed positions. Ratchet36includes a primary latch notch50, a secondary latch notch52, and an outer peripheral edge surface54. A laterally outwardly extending, raised guide surface56is also formed on ratchet36. Arrow58(FIGS. 7B and 7C) indicates a ratchet biasing member that is arranged to normally bias ratchet36toward its striker release position.

Pawl38is shown pivotably mounted to latch frame plate34about a pawl pivot post62and includes a first pawl leg segment64and a second pawl leg segment66defining a pawl engagement surface68. Roller-type engagement device40is secured to second pawl leg segment66of pawl38and includes a pair of oppositely-disposed sidewalls70defining a cage72, and a roller, shown as a spherical ball bearing74, that is retained by cage72within aligned roller slots76formed in sidewalls70. Pawl38is pivotable between a ratchet releasing position (FIG. 7B) and a ratchet holding position (FIGS. 7A, 7C and 7D). Pawl38is normally biased toward its ratchet holding position by a pawl biasing member, indicated by arrow80(FIGS. 7B and 7C).

As shown inFIG. 7B, pawl38is held in its ratchet releasing position when ratchet36is located in its striker release position due to engagement of ball74with pawl engagement surface68on pawl38and with edge surface54on ratchet36, whereby a released operating state for latch mechanism32is established. As shown inFIG. 7C, ball74is in engagement with pawl engagement surface68on pawl38and with secondary latch notch52on ratchet36so as to cause pawl38, now located in its ratchet holding position, to hold ratchet36in its secondary striker capture position. In this orientation, striker20is retained between ratchet guide channel46and fishmouth slot48in latch plate34to hold door16in a partially-closed position and establish a secondary latched state for latch mechanism32. Finally,FIGS. 7A and 7Dillustrate pawl38located in its ratchet holding position with ball74in engagement with pawl engagement surface68on pawl38and with primary latch notch50on ratchet36such that pawl38holds ratchet36in its primary striker capture position so as to hold door16in its fully-closed position and establish a primary latched operating state for latch mechanism32.

Latch release mechanism33is shown schematically to be connected to first pawl leg segment64of pawl38. Latch release mechanism33functions to cause movement of pawl38from its ratchet holding position into its ratchet releasing position when it is desired to shift latch mechanism32into its released operating state. An inside latch release mechanism (see cable80inFIGS. 3-5) connects inside handle23to latch release mechanism33to permit manual release of latch mechanism32from inside the passenger compartment of vehicle10. Likewise, an outside latch release mechanism (see cable82inFIGS. 4-5) connects outside handle21to latch release mechanism33to permit manual release of latch mechanism32from outside of vehicle10.

In addition, a power release actuator, also referred to as power actuator102, associated with actuator module24, is shown inFIGS. 7A-7Dschematically connected to latch release mechanism33. It is to be recognized any suitable power actuator arrangement is considered herein, such as disclosed in US Publication No. 2019/0136590, filed under U.S. application Ser. No. 16/182,790 on Nov. 7, 2018, owned by Applicant herein, which is incorporated herein by way of reference in its entirety. Actuation of power release actuator102causes latch release mechanism33to move pawl38from its ratchet holding position into its ratchet releasing position. As will be detailed, power release actuator102is an electric motor-driven arrangement. A ratchet switch lever (not shown) is mounted to ratchet36and works in cooperation with a ratchet release sensor (not shown) to provide a “door open” signal when ratchet36is located in its striker release position and a secondary latched sensor (not shown) to provide a “door ajar” signal when ratchet36is located in its secondary striker capture position. As is well known, these sensor signals are used by a latch control system integrated into actuator module24to control operation of power release actuator102.

Referring again toFIG. 6, actuator module24is generally shown to include an ECU/actuator assembly110and an ECU cover112, which together are secured to latch housing30of latch module22via attachment arrangement26. ECU/actuator assembly110generally includes a housing plate114, power actuator102, and a control unit116. As will be described in more detail, power actuator102is pre-assembled prior to mounting on housing plate114and generally includes a support member, also referred to as carrier plate120, an electric motor122mounted to carrier plate120and having a motor shaft194driving a pinion gear124, a power release gear, also referred to as drive gear126, in constant meshed engagement with pinion gear124and having an actuation feature128, such as an upstanding pin or cam member, by way of example and without limitation, configured to interact in operable communication with, either directly (engaging) or indirectly via an intermediate member (operably) with latch release mechanism33, and a gear stop bumper130(FIGS. 14-16) mounted to carrier plate120.

In this non-limiting configuration, power actuator102interacts with latch module22to provide a “power release” function by actuating latch release mechanism33to cause pawl38to move from its ratchet holding position into its ratchet releasing position. However, power actuator102could additionally, or alternatively, be configured to provide one or more other “powered” functions provided by latch module22such as, for example, power cinch or power lock/unlock. According to an aspect of the present disclosure, power actuator102is associated with actuator module24instead of latch module22. Conventionally, power-operated closure latch assemblies have been configured with the power actuator installed in the latch module such that an ECU module only provided power and control signals to the power actuator. The present disclosure, in contrast, provides at least one power actuator102in combination with such an ECU module116, thereby defining the term “actuator module” as used herein, which includes the ECU/Actuator assembly110.

FIGS. 8 and 9illustrate ECU cover112disposed about housing plate114and mounted on ECU/actuator assembly110with a plurality of mounting apertures140formed in ECU cover aligned with a similar plurality of alignment bores142formed in housing plate114of ECU/actuator assembly110. A suitable fastening mechanism, such as mechanical fasteners, including rivets, screws, and bolts, by way of example and without limitation, define attachment arrangement26and are installed in aligned pairs of mounting apertures140in ECU cover112and alignment bores142in housing plate114to secure actuator module24to latch module22. ECU cover112is shown best inFIG. 9to include a plate segment143, a peripheral shroud segment144extending outwardly from a plane of plate segment143, and a plurality of upstanding enclosure segments146,148,150also extending outwardly from a plane of plate segment143, shown as extending in an opposite direction from plate segment143as shroud segment144. Enclosure segments146,148,150of ECU cover112are configured to receive and enclose distinct components associated with control unit116. Specifically, plate segment143is arranged to accommodate and enclose a printed circuit board (PCB)160(FIGS. 12 and 13) which has been encapsulated/over-molded onto a first surface of housing plate114. Likewise, enclosure segment146is a connector housing surrounding a plurality of connector contacts162extending from PCB160to define an electrical connector162. In addition, enclosure segment148is a motor housing configured to enclose electric motor122which is mounted to carrier plate120and which, in turn, is encapsulated/over-molded on the first surface of housing plate114. Finally, enclosure segment150is a capacitor housing configured to enclose one or more backup power devices, such as Super Capacitors164electrically connected to PCB160. A peripheral seal170surrounds plate segment143of housing plate114and hermetically seals the first surface of housing plate114relative to ECU cover112to prevent the ingress of fluid and other forms of potential contamination therebetween.FIGS. 10 and 11illustrate ECU/actuator assembly110with ECU cover112removed to better illustrate the components. Note thatFIG. 10best illustrates PCB160being encapsulated/over-molded onto plate segment143of housing plate114, with reference number172identifying this layer of over-mold material (material overmolded onto PCB160to encapsulate and protect PCB).

FIGS. 12 and 13illustrate control unit116assembled prior to being overmolded in fixed relation onto the first surface of housing plate114. In addition to Super Capacitors164and connector contacts162, other electrical components180,182,184and186are shown mounted to an underside surface of PCB160. These additional components are located in corresponding retention cavities formed in housing plate114, as shown in phantom inFIGS. 10 and 11. Line190(FIG. 12) indicates a motor axis for electric motor122and about which motor shaft194and pinion gear124rotates. Line192indicates a gear axis for drive gear126and about which actuation feature128rotates. Gear axis192is aligned to be generally parallel to motor axis190. In addition, motor axis190is also aligned to be generally parallel to pawl axis62′ of pawl pivot post62about which pawl38rotates. This is in stark contrast to conventional arrangements where the electric motor is housed in the latch module and has its motor axis transversely aligned relative to the pawl axis. This improved arrangement allows helical teeth to be used with pinion gear124and drive gear126instead of a worm gearset, although spur gear teeth can also be used. Note also that shaft194of motor122extends through an access port195extending through housing plate114. This is the only access port through the sealed PCB160/housing plate114interface which provides a simple and effective manner to seal the electronic components and motor housing. A closure latch assembly18is illustratively provided having a latch module, for example latch module22, including a mechanism(s) operable in a first state and in a second state, and an actuator module, for example actuator module24,24A,24B,24C,24D configured to be mounted to latch module22. The actuator module includes a housing plate, such as housing plate114,114′ having a first side199,199′ facing the latch module22when the actuator module is mounted to the latch module22, and an opposite second side201,201′ facing away from the latch module22. The housing plate includes a port, such as port195,195′195″, extending from the first side199,199′ through to the opposite second side201,201′, for example as an aperture in the housing plate, for providing a passageway through the housing plate114,114′ interconnecting the first side199,199′ to the second side201,201′. The actuator module further includes a power actuator, such as power actuator102,102′,102″, provided on the second side201,201′and including a shaft, such as the motor shaft194,194′,194″, extending through the port195,195′195″, for allowing the shaft, such as the motor shaft194,194′,194″, to, for example each, interact with the mechanism(s) of the latch module, such that the power actuator is/are for shifting the mechanism(s) from its first state into its second state, for example as a result of actuation of the shaft194,194′,194″, for example a rotation or reciprocation, of the shaft194,194′,194″. The actuator module further includes a control unit provided on the second side201,201′, such as control unit116, for controlling actuation of the power actuator. The port195,195′195″ may be provided with a seal to prevent moisture, water, debris, dirt, grease, and/or other material(s), located on the first side199,199′ from penetrating into the actuator module, or onwards to the opposite second side201,201′ via the port195,195′195″, for the first side199,199′, to prevent interaction of such materials with the electronics and motor components of the sealed actuator module.

FIGS. 14 and 15illustrate power actuator102pre-assembled as a stand-alone unit prior to mounting to housing plate114and prior to overmolded layer172enclosing PCB160. While electric motor122is illustrated as being mounted to carrier plate120prior to overmolding, pre-assembled power actuator102may not include electric motor122, which can be subsequently assembled with power actuator102subsequent to the overmolding step. Carrier plate120includes a motor mount segment200, a gear support segment202, and a bumper mount segment204. Alternatively, bumper mount segment204may be provided as a pair of bumper mount segments204provided on stop lugs220and222to be engaged by naked rivet214. A pair of screws206are used to rigidly mount a motor housing210of motor122to motor mount segment200of carrier plate120. Drive gear126is rotatably mounted on a pivot shaft, also referred to as pivot rivet212, extending from gear support segment202of carrier plate120. In addition, gear stop bumper130is mounted via a rivet214to bumper mount segment204of carrier plate120. Drive gear126is shown to define a cavity218within which gear stop bumper130is located. Stop lugs220and222formed within cavity218define the rotational limits for drive gear126due to engagement with gear stop bumper130in response to rotation of drive gear126. The amount of rotation of drive gear126required for the power release function can be selected for each application. Furthermore, a magnet226associated with a Hall Effect sensor228(FIG. 6) is attached to stop lug220. An O-ring seal230seals motor shaft194extending through housing plate114. Motor leads232are electrically connected to circuit traces on PCB160and are subsequently over-molded via over-mold layer172. The pre-assembly of electric motor122and drive gear126maintains proper mesh between pinion124and drive gear126and improves sensor activation (between magnet226and Hall Effect sensor228) due to less variation in alignment during assembly.

FIG. 16illustrates actuation feature128configured in a non-limiting arrangement as a drive pin which is oriented in relation to a sector arm250(or pawl first leg segment64ofFIGS. 7A-7D) formed on pawl38and which acts as latch release mechanism33. Specifically, rotation of drive gear126from a home position to a released position via energization of electric motor122in response to a power release command causes drive pin128to engage sector arm250and drive pawl38from its ratchet holding position to its ratchet releasing position. Following power release, electric motor122is commanded to rotate drive gear126in the opposite direction back to its home position so as to reset latch release mechanism33to subsequently allow pawl38to move back into its ratchet holding position.

Referring now toFIGS. 17 and 18, a second non-limiting embodiment of an actuator module24A for use with latch module22to define closure latch assembly18is shown to generally be configured as a slightly modified version of actuator module24. In general, actuator module24A includes ECU/actuator assembly110and a modified ECU cover112A configured to provide a recessed portion145A between plate segment143A and peripheral shroud segment144A. Recessed portion145A defines an elongated notch with a height dimension “X” and a width dimension “Y”, the specific values of which can be selected to address various different applications. One application is when a maximized glass run channel is required within door16. Housing plate (not shown) and seal (not shown) may require slight modifications as well, but the dimensions and orientation of the electronic components are not changed.

FIG. 19illustrates a third non-limiting embodiment of an actuator module24B for use with latch module22to define closure latch assembly18.FIG. 19illustrates actuator module24B with an outline of a modified version of ECU/actuator assembly110B (delineated by dashed lines) overlaid over ECU/actuator assembly110with ECU cover112removed. ECU/actuator assembly110B reduces the width of PCB160B while concomitantly increasing the length of PCB160B. As part of this, the electronics would be relocated on PCB160B. Thus,FIG. 19merely illustrates an alternative configuration for an actuator module24B providing all the functions previously disclosed in relation to actuator module24.

FIG. 20illustrates a revised version of actuation module24C according to a fourth embodiment which is generally similar to actuator module24B (FIG. 19) with the exception that the location of electric motor122and connector162have been switched on PCB160C. This switched orientation permits PCB160C to have reduced width and length dimensions in comparison to PCB160B ofFIG. 19.

FIG. 21is a block diagram of a simplified method for manufacturing and assembling actuator modules24,24A,24B,24C. In general, method300includes a series of steps and/or processes comprising:302—pre-assembling power actuator102;304—assembling electronic components onto PCB160;306—assembling power actuator102and built-up PCB160to define control unit116;308—mounting control unit116on housing plate114;310—overmolding a layer of insulating material onto PCB160to enclose PCB160relative to housing plate114to define ECU/actuator assembly110; and312—mounting ECU cover112on ECU/actuator assembly110to define the actuator module.

Now referring toFIG. 22, there is provided in accordance with an illustrative embodiment, a method1000of manufacturing an actuator module24,24A,24B,24C. The actuator module24,24A,24B,24C includes a power actuator102for shifting states of a latch module22including a latch mechanism32operable in a first state and in a second state. The power actuator102includes a carrier plate120, an electric motor122securable to the carrier plate120, the electric motor122including a motor shaft194driving a pinion gear124. The power actuator102further includes a drive gear126rotatably mounted to the carrier plate120and meshed with the pinion gear124. The method1000includes the step1002of overmolding the carrier plate120to a housing plate114comprising a first side and a second side, and the step1004of forming a port195in the housing plate114for receiving the motor shaft194therethrough extending from the first side to the second side. The method1000may further include the step1006of sealing the port195with a seal230. The method1000may further include the step1008of securing the electric motor122to the carrier plate120on the first side of the housing plate114, the step1010of positioning a control unit116for controlling actuation of the power actuator102on the first side of the housing plate114, and the step1012of connecting the control unit116to the electric motor122. The method1000may further include the step1014of aligning a hall sensor228of the control unit116with a magnet226provided on the drive gear126.

Now referring additionally toFIGS. 23 to 28, in accordance with another non-limiting configuration of the present disclosure, wherein the same reference numerals are used with an apostrophe symbol (') to designate like features, there is provided an actuator module24D, also referred to using reference numeral24′, including two power actuators102′,102″ which interact with a latch module to provide two “powered” functions by latch module22such as for example, respectively a power release and power lock/unlock. Power actuators102′,102″ are both associated with the actuator module24′ instead of with latch module22such that two power actuators102′,102″ are provided in combination with the ECU module116′, thereby defining the term “actuator module” as used herein, which includes the ECU/Actuator assembly110′. More than two power actuators may be provided for in a similar manner.

An ECU cover112′ is shown best inFIG. 23to include a plate segment143′, a peripheral shroud segment144′ extending outwardly from a plane of plate segment143′, and a plurality of upstanding enclosure segments146′,148′,150′ also extending outwardly from a plane of plate segment143′, shown as extending in an opposite direction from plate segment143′ as shroud segment144′. Enclosure segments146′,148′,150′ of ECU cover112′ are configured to receive and enclose distinct components associated with control unit116′. Specifically, plate segment143′ is arranged to accommodate and enclose a printed circuit board (PCB)160′ (FIGS. 26 and 27) which has been encapsulated/over-molded onto a first surface of housing plate114′ in a manner as described herein above. Likewise, enclosure segment146′ is a connector housing surrounding a plurality of connector contacts162′ extending from PCB160′ to define an electrical connector162′. In addition, enclosure segment148′ is a motor housing configured to now enclose two electric motors122′,122″ arranged side by side having motor shafts parallel to one another and perpendicular to a plane of PCB160′ similar to the embodiments described hereinabove, which both may be mounted to a common carrier plate120′ or to separate carrier plates, and which, in turn, is/are encapsulated/over-molded on the first surface of housing plate114′. Finally, enclosure segment150′ is a capacitor housing configured to enclose one or more backup power devices, such as Super Capacitors164′ electrically connected to PCB160′.FIGS. 25 to 27illustrate ECU/actuator assembly110′ with ECU cover112′ removed to better illustrate the components.

Line190′ (seeFIG. 26) indicates a motor axis for electric motor122′ and about which motor shaft194′ and pinion gear124′ rotate to cause associated rotation, via a gear train, of actuation feature128′ as described herein above. Line190″ (seeFIG. 26) indicates a motor axis for electric motor122″ and about which motor shaft194″ and a radially extending support125′ rotate to cause rotation of another actuation feature128″. Second actuation feature128″ is shown as directly coupled to motor shaft194″ via a projecting support125′ from motor shaft194″ to share a common rotational center e.g. coaxial about line190″. This arrangement allows a direct interaction of the actuation feature128″ with a latch module22mechanism, such as an lock/unlock lever, for example, and without gearing inter-disposed between the motor122″ and the actuation feature128″, to actuate the latch mechanism between an unlock state, an example of a first state, and a locked state, and example of a second state. Of note is that shaft194″ of motor122″ extends through an associated access port195″ extending through housing plate114′. This access port195″ is another access port through housing plate114′ in addition to access port195′ configured for receiving shaft194′ of motor122′ through the sealed PCB160′/housing plate114′ interface which provides a simple and effective manner to seal the electronic components and motor housing. Shafts194,194′,194″ are illustratively shown herein as transmitting an actuation, for example rotation197′, of an actuatable component e.g. shafts194,194′,194″ extending between a first side199′ from a second side201′ of the housing plate114′ in a sealed manner, but other types of movement of such an actuatable component may be provided, for example shafts194,194′,194″ may be provided to reciprocate along their respective axis of the shafts194,194′,194″ within the apertures195,195′,195″ to provide a pushing or pulling action on a latch mechanism, as an example and without limitation.

With reference toFIGS. 1 to 28, the closure latch assembly18described herein may be installed in a closure panel of a motor vehicle, such as for example closure panel16.

Thus, the present disclosure provides a stand-along integrated ECU and power actuator arrangement, referred to as the ECU/actuator assembly110, for use in an actuator module24,24A,24B,24C,24D configured to be mounted to an independent latch module22. Accordingly, this actuator module24,24A,24B,24C,24D can be used with different latch modules and/or different versions of the same latch module. The actuator module24,24A,24B,24C,24D of the present disclosure now includes the power actuator102, removed from the latch module22, to integrate the electronics and electrically-actuated devices into a common assembly. Advantages of the present disclosure include: the ability to test, debug and calibrate the actuator module24,24A,24B,24C,24D independently from the latch module22; increase the precision of gear position detection by providing a pre-assembled power actuator102reducing stack-up tolerance between the meshed gears and the between the gear position sensor components; and fixing the motor122, drive gear126and bumper130to a common structural component isolated from the latch housing30of the latch module22reducing noise and transmitted vibration.