Abstract:
The invention relates to a drive unit ( 100 ), with a bearing device ( 50 ) for a drive motor ( 1 ) which interacts with a gearing element ( 13 ) via a drive shaft ( 2 ) which is supported at multiple points, with a first bearing element ( 3 ) which is arranged on that side of the drive motor ( 1 ) which is opposite the gearing element ( 13 ), a second bearing element ( 4 ) which is arranged between the drive motor ( 1 ) and the gearing element ( 13 ), and a third bearing element ( 20; 20   a  to  20   h ) which is arranged on that side of the gearing element ( 13 ) which faces away from the drive motor ( 1 ), wherein the third bearing element ( 20; 20   a  to  20   h ) is arranged movably in a direction perpendicular to the longitudinal axis ( 21 ) of the drive shaft ( 2 ), and wherein the third bearing element ( 20; 20   a  to  20   h ) is accommodated in a receptacle ( 38; 38   a;    66 ) of a gearbox ( 10 ).

Description:
BACKGROUND OF THE INVENTION 
       [0001]    The invention relates to a drive unit. 
         [0002]    A drive unit is known from DE 10 2010 064 295 A1 belonging to the applicant. The known drive unit is part of a comfort drive in a motor vehicle, such as, for example, in a power window drive, a sliding roof drive, a seat adjustment drive. In particular, the known drive unit has a first and a second bearing element on both sides of a drive motor in order to support a drive shaft. The drive shaft interacts with a worm toothing having a mating toothing of a gear wheel designed as a spur gear. A third bearing element is provided on that side of the gear wheel which faces away from the drive motor, the bearing element serving to absorb or to support forces which act transversely with respect to the longitudinal axis of the drive shaft and lead to a deflection of the drive shaft. For this purpose, the known drive unit or the third bearing element thereof has a portion which engages around the drive shaft at the circumference thereof preferably with radial play and is connected via a flexible intermediate portion to a bearing region arranged in a receptacle of a gear housing. As seen overall, the single-part third bearing element is of sleeve-shaped design with a passage opening for receiving the end region of the drive shaft. It is disadvantageous in the case of the drive unit known from the document mentioned that the third bearing element, for the mounting thereof, requires a relatively large amount of space in the gear housing since the third bearing element, as seen over its entire circumference, is arranged in a corresponding receptacle of the gear housing. Furthermore, the required space for receiving the third bearing element restricts the construction space or the possibility of an axial support for the end region of the drive shaft or makes such an axial support no longer possible. It should furthermore be considered to be particularly disadvantageous that, in the event of radial play between the circumference of the drive shaft and the third bearing element, a periodic contact or striking of the circumferential surface of the drive shaft against the third bearing element occurs, typically because of component tolerances, which may be perceived as an annoying noise. 
       SUMMARY OF THE INVENTION 
       [0003]    Starting from the depicted prior art, the invention is based on the object of developing a drive unit in such a manner that said drive unit firstly requires as little construction space as possible for receiving the third bearing element in the gear housing and secondly permits a reduced noise emission and also, in addition, as simple an arrangement as possible of a device for axially supporting the drive shaft. This object is achieved according to the invention in the case of a drive unit in that the receptacle for the third bearing element, which serves for the lateral support of the drive shaft, in the gear housing is arranged with respect to the drive shaft laterally next to the drive shaft in a partial region in the circumferential direction of the drive shaft, and in that the third bearing element has a contact element which is in constant bearing contact with the drive shaft. 
         [0004]    Expressed in other words, this means that, by means of the special design of the third bearing element, the latter has to be arranged only on a single lateral region in a receptacle of the gear housing, and therefore, in contrast to the prior art, it is no longer required in the gear housing to form a receptacle for the third bearing element, the receptacle completely encircling the drive shaft in the circumferential direction. As a result, in particular, additional installation space for an axial support for the drive shaft is created. Furthermore, by means of the constant contact of the third bearing element against the drive shaft, it is ensured that no noises can arise because of the drive shaft lying or being in contact merely temporarily against or with the third bearing element. 
         [0005]    In a first structural refinement of the contact element of the third bearing element, which contact element is arranged in operative connection with the drive shaft, it is provided that the contact element has a flat contact surface on the side facing the drive shaft in such a manner that the contact surface lies linearly against the drive shaft in the direction of the longitudinal axis of the drive shaft. Such a design of the contact surface of the third bearing element makes it possible, for example, to insert the third bearing element only after the drive shaft is installed in the gear housing, thus resulting in greater flexibility in respect of different possibilities of installing the drive unit. 
         [0006]    Alternatively, however, it is also possible that the contact element of the third bearing element has, on the side facing the drive shaft, a contact surface which is curved concavely or is provided with a radius in such a manner that the contact surface lies against the drive shaft in the circumferential direction of the drive shaft. Such a design of the contact surface of the third bearing element permits an improved or increased contact of the drive shaft against the contact surface of the third bearing element. 
         [0007]    In order to ensure that the third bearing element is arranged with its contact element in constant bearing contact with the drive shaft, it is provided that the contact element is connected by at least one elastic intermediate element to a bearing portion of the third bearing element, in that the bearing portion is arranged in a form-fitting or clamping-fitting manner in the receptacle of the gear housing, and in that the intermediate element produces a contact force on the contact element in the direction of the drive shaft. The third bearing element therefore has three different functional regions: firstly, the contact element which is in constant contact with the drive shaft, secondly, the intermediate element which produces the required contact force for the contact element against the drive shaft, and, thirdly, the bearing portion which is arranged in the receptacle of the gear housing. This structural splitting of the third bearing element into three functional regions makes it possible to optimally adapt the respective functional region to its respective task. 
         [0008]    In order to avoid excessive deflections of the drive shaft such that damage to the drive unit can be eliminated, it is provided that the contact element interacts with a stop which limits the deflection of the contact element in a direction perpendicularly to the longitudinal axis of the drive shaft. The stop therefore serves to protect the parts of the drive unit, and therefore the functionality of the drive unit is ensured up to the maximum deflection of the drive shaft, at which the contact element interacts with the stop. 
         [0009]    In a first structural refinement of the stop, it is provided that the stop is formed on the third bearing element itself Alternatively, it is, however, also conceivable, in a second structural refinement, that the stop is formed on the gear housing. 
         [0010]    In order to produce the required contact force of the contact element against the drive shaft, it is provided, in a first structural refinement, that the at least one intermediate element extends substantially in a direction running perpendicularly to the longitudinal axis of the drive shaft. Such an arrangement or design of the intermediate element has in particular the advantage of a construction space, which is minimized in the direction of the drive shaft, for the third bearing element, which, for example, facilitates the arrangement of a device for absorbing axial forces of the drive shaft. 
         [0011]    Alternatively, it is, however, also conceivable for the at least one intermediate element to extend substantially in a direction running parallel to the longitudinal axis of the drive shaft. Such an arrangement or design of the intermediate element has the advantage of an improved spring action of the contact element since as a result, without increasing the construction space of the gear housing in a direction running perpendicularly to the longitudinal axis of the drive shaft, the possibility is afforded of forming the intermediate element, for example, with a relatively large length. 
         [0012]    In order always to permit secure contact of the contact element of the third bearing element against the drive shaft for the entire region of the possible deflection of the drive shaft, it is provided that the gear housing has guide regions, which are formed by wall portions, for the contact element, which guide regions extend perpendicularly to the longitudinal axis of the drive shaft and, with the formation of a clearance fit, interact with side walls of the contact element. 
         [0013]    In a preferred structural refinement of the gear housing receiving the third bearing element, it is provided that the gear housing has a basic element which is preferably of shell-shaped design and in which the receptacle for the bearing device is formed, and in that the region of the receptacle is covered by means of a cover element which is connectable to the basic element and lies against the bearing element in regions. In particular, the contact of the cover element takes place at least against the bearing portion of the third bearing element in order to ensure a defined arrangement of the bearing portion of the third bearing element in the gear housing. 
         [0014]    The third bearing element can be produced particularly simply and cost-effectively if said bearing element is designed as a single-part plastics injection molded part. Alternatively, it is, however, also conceivable for the third bearing element to be formed integrally and to be composed of a rubber-elastic material. 
         [0015]    It is preferred to provide a design of the drive unit with a supporting device which acts on an end surface of the drive shaft and force-actuates the drive shaft in the direction of the gear element. 
         [0016]    A drive unit according to the invention is preferably used in a comfort drive in a motor vehicle, such as a power window drive, a sliding roof drive, a seat adjustment drive or the like. Such a comfort drive has in particular the advantage of low noise emissions and a particularly compact construction. 
     
    
     
         [0017]    Further advantages, features and details of the invention emerge from the description below of preferred exemplary embodiments and with reference to the drawing, in which: 
           [0018]      FIG. 1  shows a drive unit according to the invention in a simplified, partially sectioned side view, 
           [0019]      FIG. 2  shows a partial region of the drive unit according to  FIG. 1  in a perspective view of a first embodiment of a bearing device according to the invention, 
           [0020]      FIG. 3  shows a third bearing unit used in the drive unit according to  FIG. 2 , in a perspective individual illustration, 
           [0021]      FIG. 4  shows a gear cover used in the drive unit according to  FIG. 2 , in a perspective illustration, 
           [0022]      FIG. 5  shows a second embodiment of a bearing device according to the invention in a gear housing, in a perspective illustration, 
           [0023]      FIG. 6  shows a third bearing element of the bearing device according to  FIG. 5  in a perspective individual illustration, 
           [0024]      FIG. 7  shows a third embodiment of a bearing device according to the invention in the gear housing in a perspective illustration, 
           [0025]      FIG. 8  shows a fourth bearing device according to the invention in the installed state in the gear housing in a perspective illustration, 
           [0026]      FIG. 9  shows the third bearing element, as is used in the bearing device of  FIG. 8 , in a perspective individual illustration, 
           [0027]      FIG. 10  shows a fifth embodiment of a bearing device according to the invention in the installed state in a gear housing, in a perspective illustration, 
           [0028]      FIG. 11  shows the installation location of the third bearing element in the drive unit according to  FIG. 10  in an enlarged, perspective individual illustration, 
           [0029]      FIG. 12  shows a sixth bearing device according to the invention in a gear housing, in a perspective illustration, 
           [0030]      FIG. 13  shows a third bearing element provided in  FIG. 12 , in a perspective individual illustration, 
           [0031]      FIG. 14  shows a seventh embodiment of a bearing device according to the invention in a gear housing, in a perspective illustration, 
           [0032]      FIG. 15  shows a third bearing element as is used in the bearing device according to  FIG. 14 , in a perspective individual illustration, 
           [0033]      FIG. 16  shows an eighth design according to the invention of a bearing device in a gear housing, in a perspective illustration, 
           [0034]      FIG. 17  shows a third bearing device as is used in  FIG. 16 , in a perspective individual illustration, and 
           [0035]      FIG. 18  shows a ninth bearing device according to the invention using a third bearing element, which is composed of a rubber-elastic material, in a gear housing, in a perspective illustration. 
       
    
    
     DETAILED DESCRIPTION 
       [0036]    Identical elements or elements having the same function are provided with the same reference numbers in the figures. 
         [0037]      FIG. 1  illustrates the basic construction of a drive unit  100  according to the invention in highly simplified form, in the manner in which said drive unit serves as part of a comfort drive in a motor vehicle. A comfort drive is understood here within the context of the invention by way of example, and not in a limiting manner, to mean a power window drive, a sliding roof drive, a seat adjustment drive or the like. 
         [0038]    The drive unit  100  has a drive motor  1  which is designed as an electric motor and has a drive shaft  2  projecting out of the housing of the drive motor  1 . The drive shaft  2  of the drive motor  1  is mounted on both sides of the drive motor  1  in a first and second bearing element  3 ,  4  which are preferably designed as a ball bearing or plain bearing. In the exemplary embodiment illustrated in  FIG. 1 , the two bearing elements  3 ,  4  are accommodated or arranged in a respective recess  5 ,  6  in a gear housing  10 , only illustrated in regions in  FIG. 1 . However, it is, of course, also possible, in a modification of the illustration of  FIG. 1 , to flange-mount the drive motor  1  onto a corresponding gear housing  10  by means of an end side of the drive motor  1 , wherein the two bearing elements  3 ,  4  are then arranged, for example, in a motor housing of the drive motor  1 . 
         [0039]    On that side of the second bearing element  4  which faces away from the first bearing element  3 , the drive shaft  2  has a portion with a toothing  11  in the form of a worm toothing. The toothing  11  interacts with a mating toothing  12  of a gear device, partially illustrated, in the form of a gear wheel  13  which is designed in the form of a spur gear and which is composed of plastic. The gear wheel  13  serves for transmitting a torque produced by the drive motor  1  to an element, not illustrated, that is to be adjusted, for example a window or a sliding roof. 
         [0040]    That end region  15  of the drive shaft  2  which faces away from the drive motor  1  interacts with a third bearing element  20  as supporting element which is designed to limit the deflection of the end region  15  of the drive shaft  1 , which deflection is caused by a force F between the toothing  11  and the mating toothing  12 , in a direction running perpendicularly to the longitudinal axis  21  of the drive shaft  2  and pointing away from the gear wheel  13 . The bearing device  50  of the drive unit  100 , serving for the mounting of the drive shaft  2 , therefore has the three bearing elements  3 ,  4  and  20 . Furthermore, the end region  15  of the drive shaft  2  interacts with a supporting device  22  which absorbs or supports longitudinal forces acting on the supporting device  22  in the direction of the longitudinal axis  21 . For this purpose, as can be seen in particular with reference to the illustration of  FIG. 2 , the supporting device  22  has a supporting plate  23  which is preferably composed of metal and which supports the drive shaft  2  in the axial direction via an elastic element  24  in the form, for example, of a cylindrical rubber element, wherein the supporting plate  23  is arranged in bearing contact with the shaft end  25 , which is preferably of spherical design. The supporting device  22  is arranged in a receiving space  26  of the gear housing  10 . 
         [0041]      FIGS. 2 and 3  illustrate the third bearing element  20  of the bearing device  50  in a first embodiment of the invention in more detail. In particular, it is seen that the third bearing element  20 , which is composed of plastic, is formed integrally and is produced by injection molding, substantially consists of three regions: the first region is formed by a block-shaped contact element  28  which has a flat contact surface  29  on the side facing the drive shaft  2 . The contact element  28  is connected to a bearing portion  35  via two intermediate elements  32 ,  33  which are arranged parallel to each other and are elastically deformable in the direction of the double arrow  31 . The bearing portion  35  which is of substantially plate-like design has, perpendicularly to a rear side  36 , a stop element  37  which is designed in the shape of a web and limits the deflection of the contact element  28  in the direction toward the bearing portion  35 , i.e. perpendicularly to the longitudinal axis  21  of the drive shaft  2 , wherein the stop element  37  is arranged in alignment with the contact element  28 . 
         [0042]    The bearing portion  35  is accommodated at least in regions in a form- or clamping-fitting manner in a receptacle  38  of the gear housing  10  laterally and next to the drive shaft  2  over a partial region of the drive shaft  2 , as viewed in the circumferential direction thereof. By contrast, the two intermediate elements  32 ,  33  are arranged with play in the receptacle  38  in order to permit deformation of the intermediate elements  32 ,  33 . The receptacle  38  has wall portions  39 ,  40  which serve as guide regions and interact via a clearance fit with side walls  41 ,  42  of the contact element  28  and which, in the event of a deflection of the contact element  28  in the direction of the stop element  37 , bring about guidance of the contact element  28  in a direction running perpendicularly to the longitudinal axis  21  of the drive shaft  2 . 
         [0043]    It is essential for the contact element  28  that the arrangement of the third bearing element  20  in the receptacle  38  is such that the contact element  28  is acted upon via the two intermediate elements  32 ,  33  against the circumference of the drive shaft  2  with a contact force such that the contact element  28  is always in bearing contact by means of its contact surface  29  with the circumferential surface of the drive shaft  2 . The contact takes place linearly here over the width of the contact surface  29  parallel to the longitudinal axis  21  of the drive shaft  2 . 
         [0044]    The receptacle  38  for the third bearing element  20  is formed in a basic element  43 , which is preferably of shell-shaped design, of the gear housing  10 , which is likewise preferably produced in the plastic injection molding process. In order, in the installed state of the third bearing element  20 , to position or to secure the third bearing element  20  in the receptacle  38 , the basic element  43  is covered at least in the region of the third bearing element  20  by a cover element  44  which can be seen in  FIG. 4 . The cover element  44  has a strip-shaped supporting body  45  which, in the mounted state of the gear housing  10 , lies with the basic element  43  against the upper side of the bearing portion  35  and therefore positions or fixes said bearing portion in the receptacle  38 . 
         [0045]      FIGS. 5 and 6  illustrate a modified third bearing element  20   a  which differs from the bearing element  20  in that the contact element  28   a  and the bearing portion  35   a  are connected via a single intermediate element  46 . In contrast to the two intermediate elements  32 ,  33  of the third bearing element  20 , the intermediate element  46 , in the installed state in the gear housing  10 , extends substantially in a direction running parallel to the longitudinal axis  21  of the drive shaft  2  such that the receptacle  38   a  in the gear housing  10  also extends substantially parallel to the longitudinal axis  21  of the drive shaft  2  (in contrast to the receptacle  38  for the third bearing element  20 ). In this case, a part of the receptacle  38  runs laterally next to the supporting device  22 . The contact element  28   a  also has a flat contact surface  29   a  for contact against the circumferential surface of the drive shaft  2  and is force-actuated by the intermediate element  46  in the direction of the drive shaft  2  in such a manner that constant contact of the contact surface  28   a  against the drive shaft  2  is made possible. On the side facing away from the contact surface  29   a,  the contact element  28   a  has a flat rear side  47  which interacts with a stop surface  48 , which is formed by a partial region of the receptacle  38   a,  in order to limit the movement of the contact element  28   a  during a deflection of the drive shaft  2 . 
         [0046]    The third bearing element  20   b  of  FIG. 7  is formed at least substantially identically to the third bearing element  20   a  according to  FIGS. 5 and 6 . Differences arise merely in the (lateral) guidance of the contact elements  28   a,    28   b.  Whereas, in the case of the contact element  28   a  according to  FIG. 5 , the guidance of the contact element  28   a  takes place in the region of a web-shaped region  49  of relatively narrow design on wall portions  39   a,    40   a  of the receptacle  38   a,  the guidance of the contact element  28   b  takes place via an enlarged region of the contact element  28   b,  which region runs in a perpendicular direction to the longitudinal axis  21 . For this purpose, for example, the one side surface  51  of the contact element  28   b  is of extended design and reaches both over the region  49  and over a region  52  which is designed to be wider than the region  49 . The side surface  51  interacts with a wall portion  40   b  which is widened in relation to the wall portion  40   a.    
         [0047]      FIGS. 8 and 9  illustrate a third bearing element  20   c  which differs from the bearing element  20   a  or  20   b  essentially in that the contact element  28   c  has a contact surface  29   c  which is of concave design or is provided with a radius R and lies in regions in the circumferential direction against the drive shaft  2 , for example over an angular range of approx. 150°. The contact surface  29   c  therefore engages around the circumferential surface of the drive shaft  2  in a form-fitting manner in regions and therefore also secures or supports the drive shaft  2  in a direction running perpendicularly to the deflection of the drive shaft  2  in the event of a deflection of the drive shaft  2 . In comparison to the flat contact surfaces  29 ,  29   a,  the contact surface  29   c  therefore lies over a larger region against the circumferential surface of the drive shaft  2 . 
         [0048]    The third bearing element  20   d,  which is illustrated in  FIGS. 10 and 11 , is of substantially block-shaped design. It can either be integrally formed on the gear housing  10 , if the gear housing  10  is composed of a suitable material, or else can be designed as a separate component. In this case, said bearing element is likewise arranged in a corresponding receptacle of the gear housing  10 . The third bearing element  20   d  has two respectively block-shaped portions, which interact with each other, in the form of a contact element  28   d  and a bearing portion  35   d  which are connected integrally to each other via an elastic intermediate element  53  of web-like design. A spring gap  54  is formed between the contact element  28   d  and the bearing portion  35   d  and permits a movement of the contact element  28   d  in the direction of the arrow  55  until the contact element  28   d  lies against the bearing portion  35   d.  That contact surface  29   d  of the contact element  28   d  which faces away from the bearing portion  35   d  is likewise of flat design, wherein the contact element  28   d  always lies under prestress against the circumferential surface of the drive shaft  2 . 
         [0049]    The third bearing element  20   e,  which is illustrated in  FIGS. 12 and 13 , extends with its bearing portion  35  next to the drive shaft  2  likewise substantially parallel to the longitudinal axis  21  of the drive shaft  2 . The bearing portion  35   e  has two pin-shaped extensions  56 ,  57  which can be anchored in corresponding openings or holes in the gear housing  10 . The bearing portion  35   e  is connected via a cylindrical intermediate element  58  to the contact element  28   e.  The contact element  28   e  in turn has a flat contact surface  29   e  for constant contact with the circumferential surface of the drive shaft  2 . It is essential that the third bearing element  20   e  is designed in the form of a torsion spring in which, in the event of a deflection of the contact element  28   e,  the latter is pivoted about a longitudinal axis  59  of the intermediate element  58  in the direction of the arrow  60 . Constant contact of the contact surface  29   e  against the drive shaft  2  is also ensured here by a corresponding shaping or design of the third bearing element  20   e.    
         [0050]    The third bearing element  20   f  which is illustrated in  FIGS. 14 and 15  is formed substantially in analogy to the third bearing element  20   d  according to  FIGS. 8 and 9 . In contrast thereto, said third bearing element  20   f  has a contact element  28   f  with a through-opening  61 , wherein the wall bounding the through opening  61  at the same time forms the contact surface  29   f.  The diameter of the through opening  61  is in particular coordinated as precisely as possible with the outside diameter of the drive shaft  2  in the contact region of the contact surface  29   f  in such a manner that there is only a clearance fit between the through opening  61  and the circumference of the drive shaft  2 , said clearance fit enabling easy installation of the third bearing element  20   f  on the drive shaft  2 . By means of a corresponding arrangement of the third bearing element  20   f,  it is also ensured here that the contact surface  29   f  is always in bearing contact with the circumferential surface of the drive shaft  2 . 
         [0051]    The third bearing element  20   g,  which is illustrated in  FIGS. 16 and 17 , corresponds approximately to the third bearing element  20   a  of  FIGS. 2 and 3 . However, in contrast thereto, the contact surface  29   g  of the contact element  28   g  is likewise formed with a radius, and therefore said contact element lies in regions against the drive shaft  2  in regions in the circumferential direction thereof. A lower and an upper region of the contact element  28   g  are connected via elastic intermediate elements  62 ,  63  to the bearing portion  35   g.  The rear side  64  of the contact element  28   g,  which rear side faces away from the contact surface  29 , is arranged spaced apart from a stop surface  65  of the bearing portion  35   g,  wherein the rear side  64  lies against the stop surface  65  in the event of an excessive deflection of the drive shaft  2 . 
         [0052]    Finally,  FIG. 18  illustrates a third bearing element  20   h  which is arranged in a slot-shaped receptacle  66  of the gear housing  10 . It is essential here that the third bearing element  20   h  is composed of a rubber-elastic material. The third bearing element  20   h  has a contact surface  29   h  which is provided with a radius and lies in regions against the circumferential surface of the drive shaft  2 . The region of the contact surface  29   h  at the same time forms the contact element  28   h,  while the region of the third bearing element  20   h,  which is located within the receptacle  66 , forms the bearing portion  35   h.  The material of the third bearing element  20   h,  which material is located between the contact surface  29   h  and the receptacle  66 , at the same time forms the elastic intermediate element  67 , wherein the contact surface  29   h  always lies (in regions) against the circumferential surface of the drive shaft  2 . 
         [0053]    The drive unit  100  provided with the third bearing element  20 ,  20   a  to  20   h  may be modified in diverse ways without departing from the inventive concept.