GB2536721A

GB2536721A - Integrated door lock sub-assembly

Info

Publication number: GB2536721A
Application number: GB1505343.2A
Authority: GB
Inventors: Cheung Leo
Original assignee: Johnson Electric SA
Current assignee: Johnson Electric SA
Priority date: 2015-03-27
Filing date: 2015-03-27
Publication date: 2016-09-28
Also published as: GB201505343D0

Abstract

An integrated door lock sub-assembly 10 for a door lock, comprises a sub-assembly support element 12 having a motor housing 18 integrally formed with a gear-support platform 18a, a motor stator 40 and rotor core 42 receivable within the motor housing 18 with the output shaft 16 having an end 52 journaled in a perimeter side wall 24 of the motor housing. A commutator 38 on the output shaft 16 engages bushes 36 carried by brush block 32 secured to the motor housing 18 and at least one gear 54 mounted for rotation on the gear-support platform 18a driven by worm 48 mounted directly or indirectly to the output shaft 16. Lid 22, secured by laser/ultrasonic welding or snap-fit, seals the housing and may be located by upstanding potions of the bearings 44b,44a. Bearing 44a and the shaft also seals the housing from contamination by grease and dirt. The end 46 of the shaft may be supported by portion 50. The arrangement prevents/limits motor contamination and prevents/limits stack-up tolerances in the sub-assembly. The sub-assembly may be used as an actuator in other applications and a induction motor with slip rings or brushless motor may be substituted.

Description

Integrated Door Lock Sub-Assembly The present invention relates to an integrated door lock sub-assembly, preferably but not necessarily exclusively for a vehicular door lock. The invention further relates to a method of integrating a door lock sub-assembly to dispense with a deep-drawn motor casing, a method of preventing or limiting contamination of an electric motor assembly, a method of preventing or limiting stack-up tolerances in an integrated door lock sub-assembly, and to a locking mechanism utilising such a door lock sub-assembly for the door of a motor vehicle. An integrated actuator assembly is also provided.

The actuation of a locking mechanism for a door lock is typically driven by a small self-contained electric motor. In a motor vehicle, the electric motor is provided to drive part of a sub-assembly which can be installed into, for example, a side door. The sub-assembly will generally include a drive transmission to couple the output of the electric motor to the locking mechanism of the door lock.

The electric motor is installed into the sub-assembly as a discrete standalone unit, comprising an operative motor assembly contained within a separate or discrete motor enclosure. This is typically formed by a process known as deep-drawing, which can be expensive.

The problem with multi-component sub-assemblies and motors is that any imprecision in the manufacture of mutually co-operating components can lead to stack-up tolerance, wherein small imperfections in the manufacture of one component lead to an imperfect fit between other components downstream in the drive train, which can result in the seizing of the operable components.

One additional problem associated with such sub-assemblies is that grease or dirt can readily attach to the electric motor, in particular at or adjacent the commutator. This results in intermittent electrical contact at or adjacent the contact brushes and therefore reduces the working lifespan and effectiveness of the locking mechanism.

It is an object of the present invention to provide a door lock sub-assembly into which the electric motor assembly is integrated to prevent or substantially stack-up tolerance in the sub-assembly.

According to a first aspect of the invention there is provided an integrated door lock sub-assembly for a door lock, the integrated door lock sub-assembly comprising: a sub-assembly support element having a gear-support platform and a motor housing provided therewith; a motor stator receivable within the motor housing; a rotor including a rotor core rotatably receivable within the motor stator, an output shaft having an end journaled in a perimeter side wall of the motor housing and engaged with the rotor core, and a commutator on the output shaft; a motor contact element on a surface of the motor housing and in electrical communication with the commutator; and at least one gear mounted for rotation on the gear-support platform, the in use output shaft directly or indirectly imparting drive to the gear.

By providing a sub-assembly having a motor housing in which the electric motor can be integrally installed by joumaling the output shaft directly into a perimeter wall of the motor housing, it is possible to ensure that stack-up tolerances are minimised advantageously reducing or eliminated the likelihood of seizure of the motive components as a result. Furthermore, the number of components utilised by the sub-assembly is reduced, resulting in a more cost-effective device.

Optionally, the gear-support platform and motor housing may be integrally formed with one another.

By providing the sub-assembly support element as a single integrally formed unit, the stack-up tolerances which would ordinarily be associated with multi-component support elements can be substantially limited Preferably, the integrated door lock sub-assembly may further comprise a gear coupling engagable with the output shaft, and this gear coupling may be releasably engagable with the output shaft. In a preferred embodiment, the gear coupling may be formed as a worm gear. Furthermore, the gear coupling may be at least in part supportable by the gear support platform.

A geared mechanism is one simple means of transmitting the drive generated by the electric motor through the output shaft to the actuatable components of the locking mechanism. Gear systems are relatively slimline in profile, and therefore a relatively large proportion of the gearing can he housed within the sub-assembly support element.

Optionally, the sub-assembly support element may be formed from plastics material.

By forming the sub-assembly support element from plastics material, laser welding can be readily used to seal an enclosing lid in place, ensuring that the electric motor assembly cannot be removed, and thereby limiting the amount of material which can ingress into the motor housing.

The output shaft may be journaled in a further perimeter wall of the motor housing at a point part way along the length of the output shaft. The output shaft may additionally or alternatively be supported at the gear support platform at an end of the output shaft external to the motor housing, in which case, there may be provided a loose-fit bearing into which the output shaft is receivable, the loose-fit bearing being engaged with the gear-support platform to provide the said support to the output shaft external to the motor housing.

By supporting the output shaft in the middle as well as at its ends, the output shaft is less inclined to sag and introduce further stack-up tolerances into the system. As an additional benefit, it may he possible to use the bearing of the journaled perimeter wall as a means of limiting further ingress of oil or grease into the motor housing. Providing a bearing for the output shaft external to the motor housing may also provide better support for the output shaft especially if provided with a loose-fit bearing to allow for some tolerance to be permitted during normal use of the locking mechanism.

Preferably, the assembly may further comprise a lid for enclosing at least the motor housing of the sub-assembly support element.

By sealing at least the motor housing, the ingress of dirt, grease, oil, or other particulate matter can be substantially reduced or even eliminated, which might otherwise clog the operative components of the electric motor, and thereby impede the function of the sub-assembly as a whole.

Preferably, the motor contact element may include at least one contact brush for engagement with the commutator, which may be spring-biased to readily receive the commutator. Additionally or alternatively, the motor contact element may be releasably engagable with the motor housing.

By providing contact brushes which are housed within the motor housing, the ingress of dirt or oil at or adjacent the terminals is prevented or limited, which can advantageously eliminate the problem of intermittent contact at the commutator of the electric motor. By riveting the contact brushes, releasably or otherwise, the motor commutator can be readily plugged into the motor housing during assembly, without worrying about the robustness of the electrical connection at the brushes.

Optionally, the motor housing may include at least one alignment element directly engagable with the motor stator. The or each alignment element may be integrally formed with the motor housing, and furthermore, the or each alignment element may be a rib complementarily shaped to an external shape of the motor stator.

In order to provide a truly integrated electric motor, it is advantageous to provide a means of aligning the electric motor assembly. As the output shaft is already supported, being joumaled into the motor housing, it stands to reason that the stationary portion of the electric motor should be correctly aligned relative to the rotor. By ensuring that the motor stator is correctly seated, relative to the rotor, the performance of the electric motor assembly can be advantageously improved.

According to a second aspect of the invention, there is provided a method of integrating a door lock sub-assembly to dispense with a deep-drawn motor casing, the method comprising the steps of: a] providing a sub-assembly support element having a gear-support platform and a motor housing provided integrally formed therewith, the gear-support platform having at least one gear mounted for rotation thereon; and IA providing in the motor housing a motor stator, a rotor having a rotor core rotatably receivable within the motor stator, an output shaft having an end joumaled in a perimeter side wall of the motor housing and engaged with the rotor core, and a commutator on the output shaft; and a motor contact element on a surface of the motor housing and in electrical communication with the commutator.

Preferably, the method may further comprise a step d] of sealing or substantially sealing at least the motor housing with a lid. Beneficially, die sealing may be via laser welding, ultrasonic welding or mechanical snap-fit. By sealing the electric motor assembly within the motor housing, it is possible to advantageously prevent or limit the amount of grease, oil, dirt or other particulate matter which may contaminate the electric motor assembly and result in a malfunction of the integrated door lock sub-assembly. Laser welding is a simple and accurate means of sealing the cavity, and does not require the use of, for example, adhesive which could otherwise contaminate the motor housing.

According to a third aspect of the invention, there is provided a method of preventing or limiting contamination of an electric motor of an integrated door lock sub-assembly, preferably in accordance with the first aspect of the invention, the method comprising the steps of: a] providing a sub-assembly support element having a gear-support platform with a sealable motor housing provided therewith; and b] providing in the motor housing a motor stator and rotor, wherein an end of the output shaft of the rotor is joumaled at a perimeter wall of the motor housing.

According to a fourth aspect of the invention, there is provided a method of preventing or limiting stack-up tolerances in an integrated door lock sub-assembly, preferably in accordance with the first aspect of the invention, the method comprising the step of providing a a sub-assembly support element having a gear-support platform and a motor housing integrally formed therewith, an output shaft of a rotor receivable in the motor housing having an end joumaled in a perimeter side wall of the motor housing, whereby a discrete electric motor is dispensed with.

According to a fifth aspect of the invention, there is provided a locking mechanism for the door of a motor vehicle, the locking mechanism comprising: an integrated door lock sub-assembly, preferably in accordance with the first aspect of the invention; an actuatable locking device; and a drive transmission means for coupling the output shaft to the actuation of the locking device. Furthermore, the drive transmission means may be a toothed gear set.

A locking mechanism utilising the integrated door lock sub-assembly will beneficially have reduced stack-up tolerances, as well as being less prone to malfunction as a result of grease, oil, dirt or other particulate contamination of the electric motor which provides the driving torque of the locking mechanism.

According to a sixth aspect of the invention there is provided an integrated actuator assembly comprising: an actuator support element having a gear-support platform and a motor housing provided therewith; a motor stator receivable within the motor housing; a rotor including a rotor core receivable within the motor stator, and an output shaft having an end journaled in a perimeter side wall of the motor housing and engaged with the rotor core; a motor winding associated with one of the rotor and the stator; a motor contact element on a surface of the motor housing and in electrical communication with the motor winding; and at least one gear mounted for rotation on the gear-support platform, the in use output shaft directly or indirectly imparting drive to the gear.

The present invention can be advantageously applied in a number of scenarios utilising integrated actuators, not just those applicable to door locks. Systems using brushless motors could also benefit from the present integration of the output shaft with the actuator support assembly.

The invention will now be more particularly described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 shows a perspective view of one embodiment of an integrated door lock sub-assembly in accordance with the first aspect of the invention; Figure 2 shows an exploded perspective view of the integrated door lock sub-assembly of Figure 1; Figure 3 shows a top plan view of the integrated door lock sub-assembly of Figure 1; and Figure 4 shows the top plan view of Figure 3 prior to the lid of the motor housing having been sealed in place.

Referring firstly to Figures 1 to 3, there is shown one embodiment of an integrated door lock sub-assembly, indicated globally at 10, for use as part of a locking mechanism for a door, such as the door of a motor vehicle.

The integrated door lock sub-assembly 10 comprises a sub-assembly support element 12, and an electric motor assembly 14 having an output shaft 16 extending therefrom.

The sub-assembly support element 12 is generally formed as a unitary housing preferably from a moulded plastics material, though housings formed from a greater number of component parts could also be considered to simplify the manufacture of the sub-assembly support element 12. The sub-assembly support element 12 includes a motor housing 18 and a gear support platform 18a. The motor housing 18 defines at least one open cavity 20, and is integrally formed with, and extends from one or more sides of, the gear support platform 18a.

Advantageously, the gear support platform 18a is integrally formed with a base 19 of the motor housing18, although it will be appreciated that it may be possible to provide these two components separately and/or engagable, if desired. As illustrated, the motor housing 18 may be provided with a lid 22 capable of enclosing and, preferably liquid-tightly, sealing at least an upper edge or rim of the cavity 20 when attached. The lid 22 could, however, be dispensed with if necessary, or could cover a majority or the entirety of the sub-assembly support element 12 In the depicted embodiment, the cavity 20 is formed as a substantially cuboidal arca, defined by four connected perimeter walls 24, upstanding from the motor housing 18. In one perimeter wall 24 is provided an access aperture 26 sized so as to allow the output shaft 16 to fit therethrough. Adjacent the access aperture 26 is provided a first bearing receiving slot 28a, with a corresponding second bearing receiving slot 28b being providing adjacent an unapertured opposing perimeter wall 24.

The sub-assembly support element 12 is preferably shaped so as to be receivable at or adjacent the object which is to be locked; in the depicted embodiment, the motor housing 18 is formed so as to he receivable within the door of a motor vehicle. The lid 22 is shaped so as to be a complementary fit with the top or upper edge 30 of the perimeter walls 24. The lid could alternatively be formed to cover a majority of the sub-assembly support unit, however, so as to also enclose the gears, for example.

Within the open cavity 20, on the base 19 of the motor housing 18 from which the gear support platform 18a integrally extends, is positioned a motor contact block 32, via which electricity can be supplied to the in use electric motor assembly 14, typically by an integrated plug connector 35, integrally formed as part of the sub-assemhly support element 12 at or adjacent the gear support platform 18a and having conductors therethrough in electrical communication with the motor contact block 32. The motor contact block 32 is here riveted to the base 19 of the motor housing 18, and this could be done in a releasable manner if so desired to allow the motor contact block 32 to be readily removed and replaced if faulty. The motor contact block 32 is installed so as to be connected to the base 19 of the motor housing 18, with electrical contacts being formed between terminals of the integrated plug connector 35 and the electrically conductive supports of the contact brushes 36.

The motor contact block 32 has an electrically-insulating support 34 which supports contact brushes 36. In the depicted embodiment, the supports of the contact brushes 36 are formed so as to be dimpled so as to receivahly engage a commutator 38 of the electric motor assembly 14; two contact brushes 36 are formed such that their supports are divergent. The commutator 38 of the rotor can then be inserted into the gap presented between the two contact brushes 36, thereby naturally engaging the commutator 38 and contact brushes 36 in electrical communication The brushes 36 are preferably spring-biased for providing electrical communication with the commutator 38, but any suitable form or number of contacts can be utilised; the present method could, for instance, be utilised with a brushless or electronically commutated motor. By utilising a brushless electric motor, the need for a commutator or slip ring is dispensed. In such a scenario, there would be provided a motor winding associated with the stator or rotor which is in electrical communication with a motor contact element. The present integrated motor housing could therefore be used as part of a permanent magnet synchronous motor or an induction motor.

The electric motor assembly 14 includes a motor stator 40 and a rotor, the rotor comprising a rotor core 42 which is attached to the output shaft 16, and the commutator 38 which is attached to the output shaft 16 adjacent to the rotor core 42. hi the depicted embodiment, the motor stator 40 is receivable around the rotor core 42 such that the output shaft 16 extends out of both ends of the motor stator 40. Rihs or carriers 43 within the cavity 20 form a part of an alignment element for the electric motor assembly 14, physically locating and holding the motor stator 40 in position.

As best shown in Figure 4, when the rotor core 42 is inserted through the motor stator 40, part of the output shaft 16 projects from each end of the motor stator 40, with the output shaft 16 being journaled at one end in a perimeter wall 24 of the motor housing 18. Firs( and second bearings 44a, 44b can therefore be provided which are engagable with the bearing receiving slots 28a, 28b so as to provide support to the output shall 16 journaled therein. A first end 46 of the output shaft 16 extends outside of the cavity 20, and is connected to a gear coupling 48, here formed as a worm gear. The gear coupling 48 is shown as being removably cngagablc with output shall 16 in Figure 2 in a loose-fit arrangement, but could easily be provided so as to be in tight-fit engagement with, or permanently connected to, the output shaft 16.

Additionally, once the first bearing 44a is inserted into the first bearing receiving slot 28a, the access aperture 26 may be physically sealed by the combination of the first bearing 44a and the output shaft 16 extending through the access aperture 26. This can advantageously prevent or limit the amount of grease or dirt which can ingress through the access aperture 26.

A further shaft support portion 50 may be provided in the gear support platform 18a which supports the first end 46 of the output shaft 16. The output shall 16 is therefore supported at both its first end 46 by the further shaft support portion 50, and also at its second end 52 by the second bearing 44b in the second bearing receiving slot 28b, the second end 52 being journaled in a perimeter wall 24 of the motor housing 18. The output shaft 16 may also be supported and journaled, as shown, part way along its length by the first bearing 44a. This limits stack up tolerance of the overall sub-assembly 10.

It will be appreciated that the support at the first end 46 by the gear support platform 18a could be provided to an end of the gear coupling 48, however, instead of directly to the output shaft 16. Furthermore, it may also be possible to support or journal the first end 46 of the output shaft 16 at the gear support platform 18a, possibly by using a loose-fit bearing which is able to tolerate some flexion or distortion of the output shaft 16 which may occur in use. In such a scenario, it will be apparent that the output shaft 16 need not also be journaled part way along its length.

The gear coupling 48 is connected to or includes a worm-wheel gear 54 which is here mounted to the gear-support platform 18a. The gear 54 may be part of a toothed gear set which acts as a drive transmission means to couple the motion of the output shaft 16 to the required motion of the locking device to be locked. It will be appreciated that a worm gear arrangement is merely one form of drive transmission set; pinion and gear, rack and pinion or other transmission arrangements are equally viable. Furthermore, the output shaft 16 could directly provide drive to the gear 54 in order to provide drive to the locking device to be actuated.

To assemble the integrated door lock sub-assembly 10, the first and second bearings 44a, 44b are attached about the output shaft 16. The motor stator 40 can be positioned about the rotor core 42 and the gear coupling 48 attached to the first end 46 of the output shaft 16.

The electric motor assembly 14 can then be inserted into the cavity 20 of the motor housing 18 of the sub-assembly support element 12, such that the first and second bearings 44a, 44b are received into the respective first and second bearing receiving slots 28a, 28b, with the first end 46 of the output shaft 16 resting in the further shaft support portion 50. The commutator 38 of the rotor 42 is brought into contact with the contact brushes 36, with the motor stator 40 being provided as a tight-fit to the ribs 43 within the cavity 20. the ribs 43 being complementarily shaped to an external shape of the motor stator 40.

Since the ribs 43 which align the motor stator 40 are integrally formed with the motor housing 18, the motor stator 40 can be readily aligned to the rotor core 42, accordingly improving the efficiency of the electric motor assembly 14.

By assembling the integrated door lock sub-assembly 10 in such a manner, an electric motor is directly formed by the combination of the sub-assembly support element 12, in particular the motor housing 18, and the electric motor assembly 14. In doing so the need for a rear housing and/or separate end caps for the electric motor is eliminated. The integrated design of the door lock sub-assembly 10 substantially reduces stack-up tolerance, since the play in the first end 46 of the output shaft 16 is determined solely by the further shaft support portion 50. The number of components required to form the integrated door lock sub-assembly 10 is also reduced in the present invention; no end cap or shaft spacers are required, since the first and second bearings 44a, 44b are directly supported within the first and second bearing receiving slots 28a, 28b Once the electric motor assembly 14 is in position, the lid 22 can be positioned so as to connect with the perimeter walls 24 of the cavity 20. The first and second bearings 44a, 44b may each extend upwardly from their sub-compartments or bearing receiving slots 28a, 28b to project above the top edge 30 of the respective perimeter walls 24, thereby acting as locators for the lid 22 as well as providing a further barrier to the ingress of particulate matter at the top edge 30 of the cavity. The lid 22 can then be sealed in place in an irremovable manner. This can be achieved by laser or ultrasonic welding the lid 22 to the perimeter walls 24, but other irremovable means of attachment can be utilised, such as adhesive. Other, less permanent, means of connection could also be considered such as a mechanical snap-fit between the motor housing 18 and lid 22.

The sealing of the lid 22 to the motor housing 18 limits the degree to which grease, oil, dirt or particulate matter can ingress into the cavity 20, which would otherwise inhibit the normal function of the electric motor assembly 14. In particular, the 20 commutator 38 is prone to malfunction in the event of grease ingress.

A further benefit of providing a commutator 38 which can be directly pressed into contact with contact brushes 36 is that the natural flexion of the contact brushes 36 ensures consistent contact between the contact brushes 36 and the commutator 38, largely preventing the problem of intermittent function due to poor terminal connection.

Furthermore, by providing an integrated door lock sub-assembly 10, it is possible to remove the burden of testing of its individual components away from the end user and/or supplier of the door, and onto the supplier of the sub-assembly 10 itself. In the event of malfunction, the sub-assembly 10 can be removed in its entirety and replaced with a functional sub-assembly 10. This advantageously removes the need to test the individual components of the sub-assembly 10.

It will be appreciated that although only one type of electric motor or motor assembly is described above, that the sealing of the electric motor assembly into the sub-assembly housing is applicable regardless of the type of operation of the electric motor, and the present invention could be used in connection with any type of electric motor for which grease ingress might result in malfunction.

Furthei lore, whilst the integrated door lock sub-assembly is primarily for use with a motor vehicle, and may be integrated as part of a side door lock or trunk lock assembly, the invention as described could readily be used with any electrically operable door lock assembly. Indeed, the present invention could be extrapolated to any integrated actuator assembly, not just those used for door-lock assemblies; provided that one end of the output shaft was journaled to the integrated motor housing, the same benefits detailed above can be achieved Either brushed or brushless motors could be used in such an arrangement.

Whilst the first and second bearings shown are Bat, they may each extend upwardly to form cover locators for seating the lid for attachment. Preferably the first shaft bearing forms a sealing element and a cover locator, whereby the cover or lid urges the first shaft bearing into its slot, thereby improving the sealing.

The first bearing may also include a grommet or rubber sealing element which forms a tight but flexible seal against the output shaft, thereby further improving the sealing of the cavity. Although the first and second bearings are preferably formed of metal, it may be envisaged that at least the first bearing may be formed of rubber or another flexible material, whereby an aperture therethrough provides an interference fit with the shaft and thus an improved seal.

Whilst both bearings are shown as being positioned inside the cavity of the sub-assembly support unit, hearings could just as easily he provided only at the first and second ends of the output shaft, for example.

It is therefore possible to provide an integrated door lock sub-assembly for a door lock which comprises a sub-assembly support element which has an integrally formed motor housing and gear support platform, the output shaft of an electric motor being journalcd directly into a wall of the motor housing. By providing the sub-assembly support element as a single component which the output shall rotates relative to, the stack-up tolerance of the device, often associated with the end caps mounting the shaft hearings, can be substantially reduced.

The words 'comprises/comprising' and the words 'having/including' when used herein with reference to the present invention are used to specify the presence of stated features, integers, steps or components, hut do not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.

It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.

The embodiments described above are provided by way of examples only, and various other modifications will be apparent to persons skilled in the field without departing from the scope of the invention herein described and defined.

Claims

Claims 1. An integrated door lock sub-assembly for a door lock, the integrated door lock sub-assembly comprising: a sub-assembly support element having a gear-support platform and a motor housing provided therewith; a motor stator receivable within the motor housing; a rotor including a rotor core rotatably receivable within the motor stator, an output shaft having an end joumaled in a perimeter side wall of the motor housing and engaged with the rotor core, and a commutator on the output shaft; a motor contact element on a surface of the motor housing and in electrical communication with the commutator; and at least one gear mounted for rotation on the gear-support platform, the in use output shaft directly or indirectly imparting drive to the gear.
2. An integrated door lock sub-assembly as claimed in claim 1, wherein the gear-support platform and motor housing are integrally formed together as one-piece.
3. An integrated door lock sub-assembly as claimed in claim 1 or claim 2, further comprising a gear coupling engagablc with the output shaft.
4. An integrated door lock sub-assembly as claimed in claim 3, wherein the gear coupling is releasably engagable with the output shaft.
5. An integrated door lock sub-assembly as claimed in claim 3 or claim 4, wherein the gear coupling is formed as a worm gear.
6. An integrated door lock sub-assembly as claimed in any one of claims 3 to 5, wherein the gear coupling is at least in part supportable by the gear support platform.
7. An integrated door lock sub-assembly as claimed in any one of the preceding claims, wherein the sub-assembly support dement is formed from plastics material.
8. An integrated door lock sub-assembly as claimed in any one of the preceding claims, wherein the output shaft is journaled in a further perimeter wall of the motor housing at a point part way along the length of the output shaft.
9. An integrated door lock sub-assembly as claimed in any one of the preceding claims, wherein the output shall is supportable by the gear-support platform at an end of the output shaft external to the motor housing.
10. An integrated door lock sub-assembly as claimed in claim 9. further comprising a loose-fit bearing into which the output shaft is receivable, the loose-fit bearing being engaged with the gear-support platform to provide the said support of the output shaft external to the motor housing.
11. An integrated door lock sub-assembly as claimed in any one of the preceding claims, further comprising a lid for enclosing at least the motor housing of the sub-assembly support element.
12. An integrated door lock sub-assembly as claimed in any one of the preceding claims, wherein the motor contact element includes at least one contact. brush for engagement with the commutator.
13. An integrated door lock sub-assembly as claimed in any claim 12, wherein the or each contact brush is spring-biased to readily receive the commutator.
14. An integrated door lock sub-assembly as claimed in claim 12 or claim 13, wherein the motor contact element is releasably engagable with the motor housing.
15. An integrated door lock sub-assembly as claimed in any one of the preceding claims, wherein the motor housing includes at least one alignment clement directly engagable with the motor stator.
16. An integrated door lock sub-assembly as claimed in claim 15, wherein the or each alignment element is integrally formed with the motor housing.
17. An integrated door lock sub-assembly as claimed in claim 15 or claim 16, wherein the or each alignment element is a rib complementarily shaped to an external shape of the motor stator.
18. An integrated door lock sub-assembly substantially as hereinbefore described. with reference to Figures 1 to 4 of the accompanying drawings.
19. A method of integrating a door lock sub-assembly to dispense with a deep-drawn motor casing, the method comprising the steps of: a] providing a sub-assembly support element having a gear-support platform and a motor housing provided integrally formed therewith, the gear-support platform having at least one gear mounted for rotation thereon; and b] providing in the motor housing a motor stator. a rotor having a rotor core rotatably receivable within the motor stator, an output shaft having an end journaled in a perimeter side wall of the motor housing and engaged with the rotor core, and a commutator on the output shaft; and a motor contact element on a surface of the motor housing and in electrical communication with the commutator.
20. A method as claimed in claim 19, further comprising a step c] of sealing or substantially sealing at least the motor housing with a lid.
21. A method as claimed in claim 20, wherein the lid is scaled via laser welding, ultrasonic welding or mechanical snap-fit.
22. A method of preventing or limiting contamination of an electric motor of an integrated door lock sub-assembly as claimed in any one of claims 1 to 18, the method comprising the steps of: a] providing a sub-assembly support element having a gear-support platform and a sealable motor housing provided therewith; and b] providing in the motor housing a motor stator and rotor, wherein an end of the output shaft of the rotor is journaled at a perimeter side wall of the motor housing.
23. A method of preventing or limiting stack-up tolerances in an integrated door lock sub-assembly as claimed in any one of claims 1 to 18, the method comprising the step of providing a sub-assembly support element having a gear-support platform and a motor housing integrally formed therewith, an output shaft of a rotor receivable in the motor housing having an end joumaled in a perimeter side wall of the motor housing, whereby a discrete electric motor is dispensed with.
24. A locking mechanism for the door of a motor vehicle, the locking mechanism comprising: an integrated door lock sub-assembly as claimed in any one of claims 1 to 18; an actuatable locking device; and a drive transmission means for coupling the output shaft to the actuation of the locking device.
25. A locking mechanism as claimed in claim 24, wherein the drive transmission means is a toothed gear set.
26. An integrated acmator assembly comprising: an actuator support element having a gear-support platform and a motor housing provided therewith; a motor stator receivable within the motor housing; a rotor including a rotor core receivable within the motor stator, and an output shaft having an end joumaled in a perimeter side wall of the motor housing and engaged with the rotor core; a motor winding associated with one of the rotor and the stator; a motor contact element on a surface of the motor housing and in electrical communication with the motor winding; and at least one gear mounted for rotation on the gear-support platform, the in use output shaft directly or indirectly imparting drive to the gear.