Modular vehicle door lock and latch system and method

Abstract

A locking and latching system of modular construction in which some of the components of the system are pre-assembled prior to their installation into the structural framework of a vehicle door. The modular construction of the lock and latch system of the present invention can include the outside and inside door handles, the outside and inside locks, the door latch itself, as well as linkages between these components. The modular components of the present invention can further facilitate the assembly process by being of a design which simplifies the process of installing them into the structural framework of a vehicle door without requiring the use of specialized tools, thereby reducing the labor costs associated with assembly.

1 . A door latch assembly for installation on a door of a vehicle, the door having an outer panel, an inner panel connected to the outer panel and defining a door cavity, the door latch assembly comprising: 
 a latch securable to the door within the cavity, the latch being actuable between a plurality of positions;    a linkage positionable within the cavity and accessible from an interior side of the inner panel, the linkage operably coupled to the latch; and    a user manipulatable control connectable to the interior panel from the interior side of the inner panel to couple to the linkage from the interior side, the user manipulatable control being operable to selectively actuate the latch through the linkage between the plurality of positions.    
   
   
       2 . The door latch assembly of  claim 1 , wherein: 
 the inner panel includes a aperture in communication between the cavity and the interior side; and    the linkage is accessible through the aperture from the interior side, the user manipulatable control being at least partially insertable through the aperture from the interior side to couple with the linkage from the interior side.    
   
   
       3 . The door latch assembly of  claim 1 , wherein: 
 the user manipulatable control includes an inside door handle; and    the plurality of positions includes an open position and a closed position.    
   
   
       4 . The door latch assembly of  claim 3 , wherein: 
 the linkage includes a cable; and    the inside door handle includes a cable actuator coupled to the cable from the interior side, the inside door handle being operable to actuate the latch through the cable actuator and cable between open and closed positions.    
   
   
       5 . The door latch assembly of  claim 1 , wherein: 
 the user manipulatable control includes an inside door handle and an inside door lock; and    the plurality of positions includes an open position, a closed position, a locked position, and an unlocked position.    
   
   
       6 . The door latch assembly of  claim 5 , wherein: 
 the linkage includes a first cable and a second cable;    the inside door handle includes a first cable actuator coupled to the first cable from the interior side; and    the inside door lock includes a second cable actuator coupled to the second cable from the interior side, the inside door handle being operable to actuate the latch through the first cable actuator and the first cable between open and closed positions, and the inside door lock being operable to actuate the latch through the second cable actuator and the second cable between locked and unlocked positions.    
   
   
       7 . The door latch assembly of  claim 1 , wherein the linkage includes a cable.  
   
   
       8 . A method of installing a door latch assembly to a door of a vehicle, the method comprising: 
 providing a latch that is actuable between a plurality of positions;    operably coupling a linkage to the latch;    securing the latch to the door within a door cavity defined by inner and outer panels;    positioning the linkage within the cavity such that the linkage is accessible from an interior side of the inner panel;    connecting a user manipulatable control to the inner panel from the interior side;    coupling the user manipulatable control to the linkage from the interior side; and    operating the user manipulatable control to selectively actuate the latch through the linkage between the plurality of positions.    
   
   
       9 . The method of  claim 8 , wherein positioning the linkage includes positioning the linkage such that the linkage is accessible through an aperture in the inner panel from the interior side, the method further comprising at least partially inserting the user manipulatable control through the aperture from the interior side.  
   
   
       10 . The method of  claim 8 , wherein: 
 connecting a user manipulatable control includes connecting an inside door handle to the inner panel from the interior side;    coupling the user manipulatable control includes coupling the inside door handle to the linkage from the interior side; and    operating the user manipulatable control includes operating the inside door handle to selectively actuate the latch through the linkage between open and closed positions.    
   
   
       11 . The method of  claim 10 , wherein: 
 operably coupling a linkage to the latch includes operably coupling a cable to the latch;    coupling the inside door handle includes coupling a cable actuator of the inside door handle to the cable from the interior side; and    operating the inside door handle includes operating the inside door handle to selectively actuate the latch through the cable actuator and cable between the open and closed positions.    
   
   
       12 . The method of  claim 8 , wherein: 
 connecting a user manipulatable control includes connecting an inside door handle and an inside door lock to the inner panel from the interior side;    coupling the user manipulatable control includes coupling the inside door handle and the inside door lock to the linkage from the interior side; and    operating the user manipulatable control includes operating the inside door handle and inside door handle to selectively actuate the latch through the linkage between open, closed, locked, and unlocked positions.    
   
   
       13 . The method of  claim 12 , wherein: 
 operably coupling a linkage to the latch includes operably coupling a first cable and a second cable to the latch;    coupling the inside door handle and inside door lock includes coupling a first cable actuator of the inside door handle to the first cable from the interior side and coupling a second cable actuator of the inside door lock to the second cable from the interior side;    operating the inside door handle includes operating the inside door handle to selectively actuate the latch through the first cable actuator and first cable between the open and closed positions and operating the inside door lock to selectively actuate the latch through the second cable actuator and second cable between the locked and unlocked positions.    
   
   
       14 . The door latch assembly of  claim 8 , wherein operably coupling a linkage to the latch includes operably coupling a cable to the latch.  
   
   
       15 . A door latch assembly for installation on a door of a vehicle, the door having an interior side, an exterior side, and an aperture communicating between the interior and exterior sides, the door latch assembly comprising: 
 a latch securable to the door on the interior side and actuable between a plurality of positions;    a linkage operably coupled to the latch; and    a bracket coupled between the latch and the linkage to position the linkage relative to the latch such that the linkage is accessible from the exterior side through the aperture when the latch is secured to the door.    
   
   
       16 . The door latch assembly of  claim 15 , further comprising a user manipulatable control insertable at least partially through the aperture from the exterior side to couple to the linkage, the user manipulatable control being operable to selectively actuate the latch through the linkage.  
   
   
       17 . The door latch assembly of  claim 16 , wherein: 
 the user manipulatable control includes an outside door handle; and    the plurality of positions includes an open position and a closed position.    
   
   
       18 . The door latch assembly of  claim 16 , wherein: 
 the user manipulatable control includes an outside door lock; and    the plurality of positions includes a locked position and an unlocked position.    
   
   
       19 . The door latch assembly of  claim 16 , wherein: 
 the user manipulatable control includes an outside door handle and an outside door lock; and    the plurality of positions includes an open position, a closed position, a locked position, and an unlocked position.    
   
   
       20 . The door latch assembly of  claim 15 , wherein the bracket is flexible.  
   
   
       21 . The door latch assembly of  claim 15 , further comprising: 
 an inside door handle operably coupled to the latch; and    an additional bracket coupled between the inside door handle and the latch to position the inside door handle relative to the latch.    
   
   
       22 . The door latch assembly of  claim 15 , further comprising: 
 an inside door lock operatively coupled to the latch; and    an additional bracket coupled between the inside door lock and the latch to position the inside door lock relative to the latch.    
   
   
       23 . The door latch assembly of  claim 15 , further comprising a cable connected between the linkage and the latch.  
   
   
       24 . The door latch assembly of  claim 15  wherein the linkage is coupled to the door.  
   
   
       25 . A method for installing a door latch assembly on a door of a vehicle, the method comprising: 
 providing a latch that is securable to the door on an interior side of the door and actuable between a plurality of positions;    operably coupling a linkage to the latch;    coupling a bracket between the latch and the linkage;    securing the latch to the door;    positioning the linkage relative to the latch with the bracket such that the linkage is accessible from an exterior side of the door through an aperture in the door.    
   
   
       26 . The method of  claim 25 , further comprising: 
 at least partially inserting a user manipulatable control through the aperture from the exterior side of the door;    coupling the user manipulatable control to the linkage; and    operating the user manipulatable control to selectively actuate the latch through the linkage between the plurality of positions.    
   
   
       27 . The method of  claim 26 , wherein: 
 at least partially inserting a user manipulatable control includes at least partially inserting an outside door handle into the aperture from the exterior side of the door;    coupling the user manipulatable control includes coupling the outside door handle to the linkage; and    operating the user manipulatable control includes operating the outside door handle to selectively actuate the latch through the linkage between open and closed positions.    
   
   
       28 . The method of  claim 26 , wherein: 
 at least partially inserting a user manipulatable control includes at least partially inserting an outside door lock through the aperture from the exterior side of the door;    coupling the user manipulatable control includes coupling the outside door lock to the linkage; and    operating the user manipulatable control includes operating the outside door lock to selectively actuate the latch through the linkage between locked and unlocked positions.    
   
   
       29 . The method of  claim 26 , wherein: 
 at least partially inserting a user manipulatable control includes at least partially inserting an outside door lock and an outside door handle through the aperture from the exterior side of the door;    coupling the user manipulatable control includes coupling the outside door lock and the outside door handle to the linkage; and    operating the user manipulatable control includes operating the outside door lock and outside door handle to selectively actuate the latch through the linkage between locked, unlocked, open, and closed positions.    
   
   
       30 . The method of  claim 25 , further comprising flexing the bracket.  
   
   
       31 . The method of  claim 25 , further comprising: 
 operably coupling an inside door handle to the latch;    coupling an additional bracket between the inside door handle and the latch; and    positioning the inside door handle relative to the latch with the additional bracket.    
   
   
       32 . The method of  claim 25 , further comprising: 
 operably coupling an inside door lock to the latch;    coupling an additional bracket between the inside door lock and the latch; and    positioning the inside door lock relative to the latch with the additional bracket.    
   
   
       33 . The method of  claim 25 , wherein operably coupling a linkage to the latch includes operably coupling the linkage to the latch with a cable.  
   
   
       34 . The method of  claim 25 , further comprising coupling the linkage to the interior side of the door.  
   
   
       35 . A door latch assembly for installation on a door of a vehicle, the door having an interior side, an exterior side, and an aperture communicating between the interior and exterior sides, the door latch assembly comprising: 
 a housing securable to the door and accessible from the exterior side through the aperture; and    an outside door lock at least partially received within the housing through the aperture from the exterior side, the outside door lock having first and second states, the outside door lock being freely removable from the housing in the first state and the outside door lock being resistant to removal from the housing in the second state.    
   
   
       36 . The door latch assembly of  claim 35 , wherein the housing is at least partially positioned within the aperture.  
   
   
       37 . The door latch assembly of  claim 36 , wherein the housing includes a recess receiving at least a portion of the door defining the aperture.  
   
   
       38 . The door latch assembly of  claim 35 , further comprising: 
 a latch securable to the door on the interior side and actuable between locked and unlocked positions, wherein:    the housing includes a linkage operably coupled to the latch;    the outside door lock couples to the linkage when the outside door lock is partially received within the housing; and    the outside door lock is operable to selectively actuate the latch through the linkage between the locked and unlocked positions.    
   
   
       39 . The door latch assembly of  claim 38 , wherein the outside door lock is operable to selectively actuate the latch by turning a key inserted into the outside door lock.  
   
   
       40 . The door latch assembly of  claim 38 , wherein the outside door lock includes a central axis and a pin positioned a distance away from and rotatable about the central axis, the pin being coupled to the linkage.  
   
   
       41 . The door latch assembly of  claim 40 , further comprising a cable connected between the linkage and the latch, wherein the linkage includes a cable actuator coupled between the pin and the cable such that the outside door lock is operable to actuate the latch through the pin, cable actuator, and cable between the locked and unlocked positions.  
   
   
       42 . The door latch assembly of  claim 35 , wherein: 
 the housing includes a cylindrical opening; and    the outside door lock is received within the cylindrical opening of the housing.    
   
   
       43 . The door latch assembly of  claim 35 , wherein the outside door lock includes a projection, the projection being retracted in the first state and extended in the second state.  
   
   
       44 . The door latch assembly of  claim 43 , wherein the projection is biased toward an extended position.  
   
   
       45 . A method for assembling a door latch assembly on a door of a vehicle, the method comprising: 
 providing an outside door lock having first and second states;    securing a housing to an interior side of the door such that the housing is accessible from an exterior side of the door through an aperture in the door;    at least partially inserting the outside door lock within the housing through the aperture from the exterior side while the outside door lock is in the first state,    changing the outside door lock from the first state to the second state after the outside door lock is at least partially inserted into the housing; and    resisting removal of the outside door lock from the housing while the outside door lock is in the second state.    
   
   
       46 . The method of  claim 45 , wherein securing a housing includes at least partially positioning the housing within the aperture.  
   
   
       47 . The method of  claim 46 , wherein securing a housing includes receiving a portion of the door defining the aperture within a recess on the housing.  
   
   
       48 . The method of  claim 45 , further comprising: 
 providing a latch actuable between locked and unlocked positions;    securing the latch to the door on the interior side of the door;    operably coupling a linkage to the housing;    operably coupling the linkage to the latch;    coupling the outside door lock to the linkage when the outside door lock is partially received within the housing; and    operating the outside door lock to selectively actuate the latch through the linkage between the locked and unlocked positions.    
   
   
       49 . The method of  claim 48 , wherein operating the outside door lock includes turning a key inserted into the outside door lock.  
   
   
       50 . The method of  claim 48 , wherein providing an outside door lock includes providing an outside door lock having a central axis and a pin positioned a distance away from and rotatable about the central axis, the method further comprising coupling the pin to the linkage when the outside door lock is partially received within the housing.  
   
   
       51 . The method of  claim 50 , wherein: 
 operatively coupling the linkage to the latch includes operatively coupling a cable actuator of the linkage to the latch with a cable; and    operating the outside door lock includes operating the outside door lock to selectively actuate the latch through the pin, cable actuator, and cable between the locked and unlocked positions.    
   
   
       52 . The method of  claim 45 , wherein: 
 at least partially inserting the outside door lock includes at least partially inserting the outside door lock within a cylindrical opening of the housing through the aperture from the exterior side while the outside door lock is in the first state;    changing the outside door lock includes changing the outside door lock from the first state to the second state after the outside door lock is at least partially inserted into the cylindrical opening; and    resisting removal of the outside door lock includes resisting removal of the outside door lock from the cylindrical opening while the outside door lock is in the second state.    
   
   
       53 . The method of  claim 45 , wherein: 
 providing an outside door lock includes providing an outside door lock having a projection that is retracted in the first state and extended in the second state;    at least partially inserting the outside door lock includes at least partially inserting the outside door lock within the housing through the aperture from the exterior side of the door while the projection is retracted;    changing the outside door lock includes extending the projection after the outside door lock is at least partially inserted into the housing; and    resisting removal of the outside door lock includes resisting removal of the outside door lock from the housing while the projection is extended.    
   
   
       54 . The method of  claim 53 , further comprising biasing the projection toward the extended position.