Abstract:
The invention provides a carrier housing assembly holding a flexible foil having conductive tracks in which the housing assembly has a plurality of parts each having a respective securing mechanism, the securing mechanisms being mutually engageable to provide a predetermined spatial relationship between the part, thereby providing the flexible foil with a predetermined spatial arrangement. The housing assembly is particularly relevant to component housing assemblies where electrical components are held in place and connected to connecter pins via the flexible foil. In a further aspect of the invention, there is provided methods for manufacturing a foil carrier housing assembly out of a flexible foil comprising conductive tracks at least one electrical component, at least one electrical contact element, at least one component housing and a carrier housing.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates to electrical component housing structures and methods for their manufacture.  
         BACKGROUND OF THE INVENTION  
         [0002]    Flexible foil carrier housing assemblies are well-known. These assemblies comprise a foil and a carrier housing. Electrical components, which can be resistors, capacitors, coils, transistors or the like, as well as electrical contact elements which can be mechanical, electrical or magnetic switches, contact pins or the like, are arranged on the foil and are electrically connected to conductive tracks of the foil.  
           [0003]    It is known from prior art to provide carrier structures which shape flexible conductor foils in space and which keep said foils in that shape. For example, an interaction between carrier structures and foils of this type is described in the German laid-open document DE 44 36 523 A1 and DE 199 40 339 A1. The carrier structures according to those documents are manufactured by injection molding around the foils with a molding mass forming said carrier structure. The shape determined for the carrier structure during the injection molding determines the shape of the foil in space. Changing the shape of the foil after the carrier structure is injection molded is disadvantageously not possible.  
           [0004]    Methods of manufacturing a foil carrier housing assembly are known from prior art.  
           [0005]    For example, the German laid-open document DE 44 36 523 A1 shows a method for manufacturing a foil carrier housing assembly wherein at first in a first method step, a foil provided with electrical components and contact elements is partially injection molded with a molding mass, such that recesses corresponding to the component housings remain in the region of the components and the contact elements, wherein subsequently in a second method step, the foil is provided with components and/or contact elements through the recesses, and wherein finally in a third method step, the partially injection molded foil is once again injection molded with said injection molding mass whereby a carrier housing is manufactured.  
           [0006]    The German laid-open document DE 199 40 339 A1, in turn, discloses a method for manufacturing a foil carrier housing assembly wherein the foil is injection molded with an injection molding mass within a molding tool, such that a carrier housing in the form of a lattice-like or net-like plastic casing is produced.  
           [0007]    The methods of the above mentioned documents have in common that it is not possible to replace the foil or the electrical element in foil carrier housing assemblies manufactured according to them, which is for example necessary in the case of a defect of the foil or the component.  
         BRIEF SUMMARY OF THE INVENTION  
         [0008]    The present invention provides a carrier structure comprising at least two portions, each portion being provided with at least one securing mechanism, such that the securing mechanisms can engage each other for generating a fixed spatial arrangement of said portions with respect to each other. In contrast to prior art, the carrier structure according to the invention is not fixed in its form after its manufacture, but can modify its shape by modifying the spatial arrangement of the portions with respect to each other. The respective arrangement of the portions with respect to each other is fixed by means of a securing mechanism. Since the carrier structure holds the foil and since thus each portion of the carrier structure likewise holds a part of the foil, the modification of the spatial arrangement of the portions with respect to each other involves a shaping of the flexible foil in space. Thereby, the shape of the foil in space can be modified also after the manufacture of the carrier housing.  
           [0009]    There are different exemplary embodiments of the carrier structure. One exemplary embodiment of the carrier structure which is realized as a carrier lattice comprising enclosing frames and transversal bridges, is especially advantageous. The lattice-like or net-like structure advantageously material-saving. Furthermore, said structure provides also after the manufacture of the carrier structure portions of the foil between the enclosing frames and the transversal bridges which are accessible from outside. Thereby, also after the manufacture of the carrier structure, for example electrical components or the like can be placed on the surface of the foil.  
           [0010]    Likewise, there are different exemplary embodiments for the securing mechanisms. For example one of mechanisms can be realized as plug-in pin and the other as plug-in socket. In this case, generating a fixed spatial arrangement between the portions of the carrier structure with respect to each other corresponds to introducing the plug-in pins into the plug-in sockets. The plug-in pins are frictionally engaged within the plug-in sockets. Therefore, the engagement between plug-in pin and the plug-in socket is removable by pulling the plug-in pin out of the plug-in socket. In case a permanent fixing of the plug-in pin within the plug-in socket has to be secured, the plug-in pin can for example be glued in the plug-in socket.  
           [0011]    The carrier structure can hold the foil in several ways. One exemplary embodiment of the carrier structure comprises holding pins and holding openings for that purpose. The holding pins of the carrier structure and the holding openings of the foil are assigned to each other in number and arrangement. In this exemplary embodiment, the carrier structure holds the foil in that the holding pins penetrate the holding openings. In order to guarantee a fixed holding of foil by the carrier structure, the heads of the holding pins can be deformed. Moreover, the holding of the foil by the carrier structure can be realized in that the foil is glued onto the carrier structure. Likewise it is possible to manufacture the carrier structure by injection molding or casting around the foil with a molding mass. In this case, the holding of the foil by the carrier structure is effected such that the molding mass adheres to the foil. Preferably, the molding mass is plastic. As far as manufacturing methods are concerned, it is advantageous if the securing mechanisms are manufactured with the manufacture of the carrier structure since in this case, the carrier structure and the securing mechanism are manufactured in one step. After the manufacture of the carrier structure by injection molding or casting, the portions of the carrier structure are moveable with respect to each other and, so to say, kept together only by the foil. In case the portions are moved with respect to each other unintendedly, a damage to the foil in the region between the two portions of the carrier structure can result. In order to avoid this, one exemplary embodiment of the invention provides breakable bridges which connect the portions of the carrier structure. The breakable bridges prevent an unintended movement of the portions with respect to each other. They may be removed before the foil is shaped in space.  
           [0012]    The foil can be provided with a plurality of electrical components and/or electrical contact elements. For example the electrical components are resistors, capacitors, coils, transistors or the like, and the electrical contact elements can be mechanical, electrical or magnetic switches, contact pins and the like.  
           [0013]    Handling the manufacture of the carrier structure is especially easy if the carrier structure is plane before the foil is shaped in space. This means, that the enclosing frames, the transversal bridges and, if present, the breakable bridges of the carrier structure as well as the foil extend in a plane.  
           [0014]    One aspect of the invention provides a method for manufacturing a component carrier structure comprising the steps of: manufacturing the carrier structure and securing mechanisms by injection molding or casting around a foil, and generating an engagement between the securing mechanisms. Thus, by adding to step of manufacturing the carrier structure by injection molding or casting around the foil one additional method step of manufacturing an engagement between the securing mechanisms, modifying the spatial arrangement of the portions of the carrier structure with respect to each other for shaping the foil in space is possible also after a carrier structure is manufactured.  
           [0015]    In case that the two portions of the carrier structure are connected by breakable bridges, the latter may be removed before the foil is shaped in space.  
           [0016]    In one exemplary embodiment of the method, a further step is performed which comprises the manufacture of a carrier housing by injection molding or casting the carrier structure with a molding mass. In this case, the carrier structure represents an intermediary tool maintaining the shape of a foil in space for manufacturing the carrier housing. After the carrier housing is manufactured, the carrier structure is a part of the carrier housing; in particular if the carrier structure and the carrier housing are manufactured using the same molding mass, the carrier housing and the carrier structure cannot be distinguished from each other.  
           [0017]    It is possible, to provide the foil with electrical components and/or electrical contact elements at various points in the manufacture process.  
           [0018]    According to a second aspect of the invention, there is provided a method for manufacturing an electrical component housing assembly including a flexible foil incorporating a plurality of conductive tracks, said conductive tracks being selectively electrically connected to respective contact elements and at least one electrical component located within a component housing, said method comprising the steps of: [ 1   a ] mechanically and electrically connecting the foil to the electrical component and the electrical contact element, [ 1   b ] manufacturing at least one open component housing around at least one of the electrical components by injection molding or casting, [ 1   c]  sealing the open component housings by injection molding or casting, and [ 1   d ] mechanically connecting the sealed component housings to the carrier housing. In contrast to the prior art methods, mechanically connecting at least one part of the foil and the carrier housing is provided as a last step in the method according to the invention. Preferably, the connection between the foil and the carrier housing enables a quick replacement of the foil and/or the electrical component.  
           [0019]    In step [ 1   a ], the electrical components and the contact elements can be connected to the foil in several ways. The more important of these ways are soldering or welding, particularly laser welding.  
           [0020]    In step [ 1   c ], sealing the component housings can be performed, such that the components contained in the component housings are totally covered by injection molding mass. In this case, the component is completely encapsulated and therefore optimally protected from harmful external influences. Additionally, sealing the component housings in step [ 1   c ] can be performed, such that the components contained in the component housings are nearly partially covered by the injection molding mass which is for example advantageous when the component comprises connection portions to which further electrical components are connected to later or if the component is to be trimmed later. In this case, the component housings can also be completely sealed during a further step performed after step [ 1   d].    
           [0021]    Furthermore, there is provided a second method for manufacturing an electrical component housing assembly including a flexible foil incorporating a plurality of conductive tracks, said conductive tracks being selectively electrically connected to respective contact elements and at least one electrical component located within a component housing, said method comprising the steps of: [ 2   a ] manufacturing a component housing, [ 2   b ] manufacturing the component housing by injection molding or casting contact element, and [ 2   c ] mechanically and electrically connecting the foil, the component housing and the carrier housing. This method according to the invention is likewise distinguished from prior art by mechanically connecting a foil and the carrier housing as a last step. According to the above explanations, the second method enables a quick replacement of the foil and/or the electrical components, as well.  
           [0022]    There is also provided a still further method of manufacturing an electrical component housing assembly including a flexible foil incorporating a plurality of conductive tracks, said conductive tracks being selectively electrically connected to respective contact elements and at least one electrical component located within a component housing, said method comprising the steps of: [ 3   a ] manufacturing component housings, [ 3   b ] manufacturing the carrier housing by reverse side injection molding or casting the foil and [ 3   c ] mechanically and electrically connecting the carrier housing, the contact elements and the component housings. In accordance with the two methods already explained, this method likewise provides mechanically connecting as a last step whereby also in this case, a quick replacement of the foil and/or the electrical component is enabled.  
           [0023]    As far as manufacturing the component housings in step [ 2   a ] or [ 3   a ] is concerned, a method is especially preferred which comprises the following steps: [A] manufacturing a punched lattice comprising a plurality of structurally identical portions by punching a sheet consisting of electrically conductive material, or providing a circuit board having a plurality of structurally identical portions, [B] manufacturing open component housings by injection molding or casting each of the structurally identical portions, [C] mechanically and electrically connecting the open component housings to the electrical components by soldering or welding, preferably laser welding, the components within the component housings, such that the electrical component are conductively connected to the punched lattice or the circuit board, [D] sealing the component housings by injection molding or casting the component housings, and [E] separating the component housings by cutting the punched lattice or the circuit board. By using this method, a great number of component housings can quickly and easily be manufactured.  
           [0024]    Step [ 2   c ] or [ 3   c ] proving mechanically and electrically connecting can be realized in different ways. For example, the foil can have in the region of the conductive tracks openings, and the component housings can have pin like punched lattice connecting portions assigned in number and arrangement to said openings. In this case, mechanically and electrically connecting in step [ 2   c ] or [ 3   c ] means introducing the punched lattice connecting portions into the openings, generating a contact between the punched lattice connecting portions and the conductive tracks and, if necessary, soldering or welding (laser welding) the punched lattice connecting portions to the conductive tracks.  
           [0025]    Mechanically connecting according to step [ 1   d ], [ 2   c ] or [ 3   c ] can be realized in different ways. For example, the carrier housing can have a recess the cross section of which corresponds to the shape of foil. In this case, mechanically connecting according to step [ 1   d ], [ 2   c ] or [ 3   c ] corresponds to introducing the foil into the recess. Alternatively or additionally, the carrier housing can have connecting protrusions, and the foil can have connecting openings assigned in number and arrangement to the connecting protrusions. In this case, mechanically connecting according to step [ 1   d ], [ 2   c ] or [ 3   c ] means introducing the connecting protrusions into the connecting openings respectively assigned and subsequent pressure deforming the connecting protrusions. Alternatively or additionally, the carrier housing can have connecting pockets having receiving grooves, and the component housings can have engaging edges assigned in number and arrangement to the receiving grooves. In this case, mechanically connecting according to step [ 1   d ], [ 2   c ] or [ 3   c ] means introducing the engaging edges into the receiving grooves until the component housings are completely received within the connecting pockets.  
           [0026]    A preferred embodiment of the method provides that the conductive tracks of the foil are copper tracks.  
           [0027]    Preferably, the component housings and a carrier housing are made of plastic. 
       
    
    
     INTRODUCTION TO THE DRAWINGS  
       [0028]    The invention will now be described by way of example with reference to the following drawings in which:  
         [0029]    [0029]FIG. 1 shows an exemplary embodiment of a carrier structure according to the invention before a foil is shaped in space,  
         [0030]    [0030]FIG. 2 shows a part of the carrier structure according to FIG. 1 in an enlarged scale,  
         [0031]    [0031]FIG. 3 shows the carrier structure according to FIG. 1 after the foil has been shaped in space,  
         [0032]    [0032]FIG. 4 a part of the carrier structure of FIG. 3 in an enlarged scale,  
         [0033]    [0033]FIG. 5 a carrier housing.  
         [0034]    [0034]FIG. 6 shows a foil after step [ 1   a ] of a first method is performed.  
         [0035]    [0035]FIG. 7 shows a part of another foil after step [ 1   b ] of the first method is performed.  
         [0036]    [0036]FIG. 8 shows a part of foil according to FIG. 2 after a step [ 1   c ] of said first method is performed.  
         [0037]    [0037]FIG. 9 shows a foil carrier housing assembly after a step [ 1   d ] of said first method is performed.  
         [0038]    [0038]FIG. 10 shows a part of said foil carrier housing assembly according to FIG. 4 in a larger scale.  
         [0039]    [0039]FIG. 11 shows a punched lattice before a plurality of component housings according to step [ 2   a ] of said second method is performed.  
         [0040]    [0040]FIG. 12 shows said plurality of said component housings according to step [ 2   a ] of said second method.  
         [0041]    [0041]FIG. 13 shows a component housing according to step [ 2   a ] of said second method.  
         [0042]    [0042]FIG. 14 shows a carrier housing after a step [ 2   b ] of a second method according to the invention is performed.  
         [0043]    [0043]FIG. 15 shows a part of a foil carrier housing assembly after a step [ 2   c ] of said second method is performed.  
         [0044]    [0044]FIG. 16 shows a larger view of a foil carrier housing assembly after a step [ 3   b ] of a third method according to the invention is performed.  
         [0045]    [0045]FIG. 17 shows a second view onto said foil carrier housing assembly according to  
         [0046]    [0046]FIG. 11 after a step [ 3   c ] of said third method is performed. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0047]    [0047]FIG. 1- 5  show a first aspect of the invention describing a component housing assembly. FIG. 1 shows a carrier structure  1  in the form of is a plane carrier lattice  3 . Carrier lattice  3  comprises an enclosing frame  5  and a plurality of transverse bridges  7 . Enclosing frame  5  encloses the carrier lattice  3  whereas the transverse bridges  7  connect different portions of the enclosing frame  5  or different portions of enclosing frame  5  and other transversal bridges  7 .  
         [0048]    A flexible foil  9  is imbedded within carrier lattice  3 . Foil  9  has a shape corresponding to that of carrier lattice  3 ; therefore the enclosure of foil  9  is adjacent to the enclosing frame  5  of carrier lattice  3 . Foil  9  lies flat on enclosing frame  5  and transversal bridges  7  of carrier lattice  3  and adheres to them. Therefore, foil  9  just like carrier lattice  3  is planar and extends in the same extension plane as the latter. Since foil  9  adheres to carrier lattice  3 , carrier lattice  3 , holds foil  9 . As a consequence, carrier lattice  3  determines the spatial shape of foil  9 . As far as the state depicted in FIG. 1 is concerned, this means that plane carrier lattice  3  or plane carrier structure  1  involve the plane shape of flexible foil  9 .  
         [0049]    Foil  9 , however, can be held by carrier structure  1  in a different way too. For example, foil  9  can be glued onto carrier structure  1 . Moreover, carrier structure  1  can be provided with holding pins which penetrate holding openings arranged in foil  9  and the heads of which are deformed to hold the foil  9  in place.  
         [0050]    Foil  9  comprises a plurality of conductive tracks  11 . Conductive tracks  11  are arranged at the surface of foil  9  and form a layout thereon. Different arrangements of conductive tracks  11  are likewise possible, for example a multilayer foil where the conductive tracks are arranged inside the foil.  
         [0051]    Conductive tracks  11  end adjacent to a lateral enclosing bridge  13  of carrier lattice  3 . Here, lateral enclosing bridge  13  comprises a plurality of contact through-holes  15 . Each conductive track  11  of foil  9  is assigned to one contact through hole  15 . As it can be seen in FIG. 3, an electrical contact element  19  being realized as contact pin  17  is frictionally engaged in each of contact through holes  15 . Contact elements  19  are conductively connected to conductive tracks  11  respectively assigned thereto. By means of electrical contact elements  19 , the conductive tracks of the foil may be connected to a power or current source (not shown), or other parts of an electrical circuit.  
         [0052]    Moreover, a plurality of electrical components  21  is arranged on foil  9 . In the depicted exemplary embodiment, electrical components  21  are realized as resistors which are conductively connected to conductive tracks  11  of foil  9 . As a consequence, there is a continuous conductive connection between contact pin  17  (FIG. 3), conductive tracks  11  and components  21 .  
         [0053]    Carrier structure  1  comprises three portions namely a portion  23   a  which is marked by a continuous closed line in FIG. 1, a portion  23   b  which is marked by a dashed closed line in FIG. 1, and a portion  23   c  which with respect to carrier structure  1  of FIG. 1 represents the complement with respect to portions  23   a  and  23   b,  i.e., it corresponds to a portion  23   c  of carrier structure  1  in FIG. 1 which is neither marked by the continuous nor by the dashed line.  
         [0054]    In portion  23   a,  foil  9  is provided with two electrical components  21 , and in portion  23   b  with one electrical component  21 . Portions  23   a  and  23   b  are in the form of an electrical component housing, providing a degree of protection for electrical components located therein.  
         [0055]    [0055]FIG. 2 shows portions  23   a  and  23   b  in an enlarged scale wherein portion  23   a  of carrier structure  1  along with a part of portion  23  are shown in the left part of FIG. 2 whereas portion  23   b  of carrier structure  1  along with a part of portion  23   c  are shown in the right half of FIG. 2.  
         [0056]    The left half of FIG. 2 clearly shows that portions  23   a  and  23   c  are connected to each other via a transition region  25  of foil  9  as well as by a breakable bridge  27 . Breakable bridge  27  connects portion  23   a  to  23   c  of carrier structure  1  in the region of transition region  25  of foil  9 , i.e., breakable bridge  27 , so to say, replaces enclosing frame  5  in this region.  
         [0057]    Adjacent to transition region  25 , carrier structure  1  comprises four securing mechanisms  29 . Two securing mechanisms  29  are assigned to portion  23   a  of carrier structure  1 , and two securing mechanisms  29  are assigned to portion  23   c  of carrier structure  1 . Each securing mechanism  29  assigned to portion  23   a  is a plug-in pin  31 , and each securing mechanism  29  assigned to portion  23   c  is a plug-in socket  33 . One plug-in pin  31  and one plug-in socket  33  are arranged opposite to each other in the region of enclosing frame  5  of carrier structure  1 . Plug-in pins  31  and plug-in sockets  33  are formed, such that they can engage each other and such that plug-in pin  31  is frictionally engaged within plug-in socket  33 .  
         [0058]    It is clear that after removing breakable bridges  27 , plug-in pins  33  of portion  23   a  of carrier structure  1  are introducible into plug-in socket  33  of portion  23   c  of carrier structure  1 .  
         [0059]    The above description of portion  23   a  is correspondingly applicable to portion  23   b  of carrier structure  1  which is shown in the right half of FIG. 2.  
         [0060]    The state of carrier structure  1  in which plug-in pins  31  are introduced into plug-in sockets  33  of carrier structure  1  is shown in FIGS. 3 and 4.  
         [0061]    A comparison between the state of carrier structure  1  according to FIGS. 1 and 2 and that according to FIGS. 3 and 4 clearly shows, that the former is characterized by portions  23   a  and  23   c  and thus those parts of the foil  9  which are held by portions  23   a  and  23   c  extend parallel and within the same plane whereas with respect to the latter, both portions  23   a  and  23   c  and thus the parts of foil  9  held by those portions  23   a  and  23   c  include an angle of approximately 90°. The same holds good for portions  23   b  and  23   c  of carrier structure  1 .  
         [0062]    Thus, the plane arrangement according to FIGS. 1 and 2 has turned into a spatial arrangement by the mutual engagement of securing mechanisms  29 ; securing mechanisms  29 , therefore serve for shaping flexible foil  9  in space. Flexible foil  9  is held in a spatial shape by carrier structure  1  according to the invention. It is curved in transition regions  25  between portions  23   a  and  23   c  or portions  23   b  and  23   c,  respectively, which can in particular be seen in FIG. 4.  
         [0063]    [0063]FIG. 5 shows a carrier housing  35 . Carrier housing  35  is not lattice like or net like but is rather continuous in shape. Carrier housing  35  is manufactured by injection molding carrier structure  1  whereby carrier structure  1  has become a part of carrier housing  35 . Carrier structure  1  and carrier housing  35  are manufactured out of the same plastic molding mass; therefore, carrier structure  1  and carrier housing  35  are hardly distinguishable from each other. Only contact pins  17  and electrical components  21  are visible at the manufactured carrier housing  35 .  
         [0064]    In the following, the method of manufacturing the carrier structure I will be described.  
         [0065]    The state represented in FIGS. 1 and 2 corresponds to a state in which carrier structure  1  and securing mechanisms  29  are manufactured by injection molding foil  9 . The state according to FIGS. 3 and 4 corresponds to a state after securing mechanisms  29  have engaged each other.  
         [0066]    Between these states, breakable bridges  27  are removed. This removal may either be simply by bending or the bridges may actually be cut away.  
         [0067]    The advantages of the method according to the invention by using a carrier structure according to the invention are particularly clear if one further method step follows in which carrier housing  35  is manufactured by injection molding or casting carrier structure  1  with a molding mass. Carrier structure  1 —which is in this case also called “auxiliary molding structure” mainly serves for fixing foil  9  in a desired spatial shape before carrier housing  35  is manufactured by injection molding carrier structure  1 .  
         [0068]    Providing foil  9  with electrical components  21  or electrical contact elements  19  can be performed both before manufacturing carrier structure  1 , as well as between the state according to FIGS. 1 and 2 as well as between the steps according to FIGS. 3 and 4.  
         [0069]    Particular alternative arrangements to the structure  1  include only a single securing mechanism associated with each component housing.  
         [0070]    A further aspect of the invention comprising an electrical component housing assembly is shown in FIGS.  6 - 17   
         [0071]    FIGS.  6  to  10  illustrate a first method of this further aspect of the invention.  
         [0072]    [0072]FIG. 6 shows a flexible foil  104 . Said flexible foil  104  is preferably of polyimide but it can, be of other materials conveying flexibility, for example polyester or the like. Said flexible foil  104  comprises a plurality of conductive tracks  102 . Said conductive tracks  102  are arranged according to a preferred layout on the surface of said flexible foil  104 . The tracks  102  are preferably of copper and manufactured according to known methods, for example etching a copper layer deposited on said flexible foil  104 . Additionally, a plurality of electrical contact elements  108  are attached to said foil  104 ,. Each of said contact elements  108  is preferably soldered to a respective conductive track  102  and is thereby electrically connected thereto. Also, said flexible foil  104  incorporates a plurality of connecting openings  118 , the purpose for which will be described later. Said connecting openings  118  are holes penetrating the flexible foil  104 .  
         [0073]    [0073]FIG. 6 shows said flexible foil  104  after a step of connecting said foil  104  and said contact elements  108  to each other, both mechanically and electrically.  
         [0074]    In FIG. 7, another view of the foil  104  is shown in which two electrical components  106  have been soldered to said conductive tracks  102 . As shown in FIG. 2, both components  106  are identical and arranged in parallel in a compact module. Said two components  106  are arranged within a component housing  110 . Said component housing  110  comprises a surrounding wall  111  an upper edge of which is slightly higher than said two components  106 . At a lower edge, facing towards the foil, an engaging edge  124  in the form of a surrounding protrusion is formed. Said component housing  110  is manufactured by means of injection molding. As shown in FIG. 7, said component housing  110  is arranged at a terminating end  113  of said foil  104 . FIG. 8 shows the arrangement of FIG. 7 after sealing by the injection of molding mass  115 .  
         [0075]    [0075]FIG. 9 shows the foil  104  arranged within a carrier housing  112 . Said foil  104  is accommodated in a recess  114  of said carrier housing  112  and lies flat at the bottom of said recess  114 . Thus, said carrier housing  112  and said foil  104  form a foil carrier housing assembly  100 .  
         [0076]    A connection between the foil  104  and the carrier housing  112  is provided by several means. The carrier housing  112  comprises a plurality of connecting protrusions  116  extending upwards from the bottom of said recess  114 . Said connecting protrusions  116  correspond in number and arrangement to the connecting openings  118  of said foil  104  and penetrate those. The foil  104  is secured by pressure deforming the connecting protrusions, i.e. the ends thereof are thickened, such that such the connecting openings  118  of said foil  104  cannot slide over the connecting protrusions  116  of said carrier house  112 .  
         [0077]    As a second mechanical means for generating a connection between the foil  104  and the carrier housing  112 , the carrier housing  112  comprises two connecting pockets  122 . According to exemplary embodiment of FIG. 9, said connecting pockets  122  are arranged at the edge of said carrier housing  112  and extend in a plane extending perpendicular to the extension plane of said carrier housing  112  with a recess for receiving the component housing  110 .  
         [0078]    As shown in FIG. 10, said connecting pockets  122  are provided with a receiving grooves  120  at two opposite sites. The dimensions of said receiving grooves  120  are chosen, such that they can hold the engaging edges  124  of said component housing  110 . Preferably, the edges  124  are frictionally restrained in said grooves  120 .  
         [0079]    The component housing assembly  100  according to FIGS. 9 and 10 is in a state in which the sealed component housing  110  and the carrier housing  112  are mechanically connected to each other.  
         [0080]    A second method of the invention is shown by FIGS.  11 - 15  wherein FIGS.  11 - 12  show the manufacture of a plurality of component housings  110 .  
         [0081]    [0081]FIG. 11 shows a punched lattice array  128 . Said punched lattice  128  forms a lattice array of an electrically conductive material and is manufactured by punching a metal sheet. The punched apertures comprises a plurality of structurally identical portions  126 . Said structurally identical portions  126  are arranged in a regular lattice structure and thus form said punched lattice  128 .  
         [0082]    In FIG. 12, there is a surrounding wall  111  arranged each of said structurally identical portions  126  of said punched lattice  128 . Said wall  111  is manufactured by injection molding around the structurally identical portions  126  and extends in a plane extending perpendicular to the extension plane of the punched lattice  128 . Said wall is approximately rectangular in shape and forms a hollow therewithin. Within said hollow an electrical component  106  is arranged. Said electrical component  106  is soldered to the punched lattice  128  and conductively connected thereto. Each structurally identical portions  126  of said punched lattice  128  forms together with the electrical components  106  and the surrounding wall  111  a respective component housing  110 .  
         [0083]    The final manufactured component housing  110  is shown in FIG. 13. As showing in FIG. 13, each component housing  110  has been sealed by means of a molding mass indicated by a hatched area, and the respective component housings  110  separated from each other by cutting separating points  129  of said punched lattice  128 .  
         [0084]    The carrier housing  112  according to the second method of the invention is shown in FIG. 14. The housing  112  is manufactured by injection molding around the electrical contact elements  108 . During the injection molding, the recess  114 , the connecting protrusions  116  extending outwardly way from the bottom of the recess  108 , the connecting pockets  122  as well as the receiving grooves  120  provided therein are formed.  
         [0085]    The steps of providing the carrier housing and the component housing can be performed simultaneously.  
         [0086]    [0086]FIG. 15 shows the state after the carrier housing  112 , the component housing  110  and the flexible foil  104  have been connected together. FIG. 15 especially shows the type of electrical connection between the conductive tracks  102  and the component housing  110 . For this purpose, openings  130  are arranged to some of the conductive tracks  110 , the openings being through-holes penetrating the flexible foil  104 . The interior of each opening  130  is plated with a conductive material. Said openings  140  are penetrated by punched lattice connecting portions  132  of said component housings  110 . The punched lattice connecting portions  132  correspond to the separating points  129  of the punched lattice  128 . The connecting portions are conductively connected to the electrical component  106  of the respective component housing  110 . The connecting portions penetrate the openings  130  and are soldered, welded or conductively glued thereto. Therefore they are likewise connected to the conductive tracks  102  respectively assigned. As a consequence, there is a complete conductive connection between certain conductive tracks  102  and said components  106  of said component housings  110 .  
         [0087]    Finally, FIGS.  16 , and  17 , in combination with FIGS. 11, 12, and  13 , show the manufacture of a component carrier housing assembly  100  according to a third method.  
         [0088]    Manufacturing of the component housings  110  has been previously explained with reference to FIG. 11- 13 .  
         [0089]    [0089]FIG. 16 shows a foil  104  and a carrier housing  112  after a step of reverse side injection molding to the foil  104 , i.e., the connection between the foil  104  and carrier housing  112  is effected such that the former adheres to the latter. In FIG. 16, no connecting protrusions  116  are provided at the carrier housing  112 , and no connecting opening  118  are provided at the foil  104 .  
         [0090]    Finally, FIG. 17 shows the carrier housing after the electrical contact elements  108  and the component housings  110  have been mechanically and electrically connected to the carrier housing  112  and the foil  104 .  
         [0091]    Alternative arrangements for the individual components will be apparent to a skilled person. For example, instead of the grooves  120  and corresponding ridges  124  in the component housings, an arrangement of a snap fitting using retaining lugs could be provided. As such, it will be apparent to a skilled person that changes and modifications may be made without departing from the spirit and scope of the invention as set forth herein and shown in the accompanying drawings and as defined in the following claims.