INFLATOR, METHOD OF MANUFACTURING THE SAME AND MODULE INCLUDING SAID INFLATOR

Abstract

An inflator as well as a method of manufacturing an inflator, a module including an inflator and an airbag module. In an inflator, especially for a protective device in a vehicle, comprising plural components a sealant is applied in the area of abutting components, especially a sealant which adheres to both abutting components.

Claims

1. An inflator comprising: a first component (112) and a second component (114) connected to the first component (112) by an injected plastic base (116) by at least partially surrounding both components (112, 114) by injection molding, wherein the first component (112) has an adhesive film (142) applied before injection molding in a contact area (140) with the plastic base (116).

2. An inflator according to claim 1, wherein the first component (112) is made of metal, ceramic and/or plastic material

3. An inflator according claim 1, wherein the first component (112) is an inflator housing or forms a partial element of an inflator housing.

4. An inflator according to claim 1, wherein the second component (114) is a prefabricated igniter closed to the outside.

5. An inflator according to claim 1, wherein the first component (112) has an orifice (120) for receiving and mounting the second component (114) the edge (122) of which is embedded in the plastic base (116) during injection molding.

6. An inflator according to claim 1, wherein the adhesive film (142) covers only part of the portion of the first component (112) surrounded by injection molding.

7. An inflator according to claim 1, wherein the adhesive film (142) covers the entire portion of the first component (112) surrounded by injection molding.

8. An inflator according to claim 1, wherein the adhesive film (142) projects from the portion of the first component (112) surrounded by infection molding.

9. An inflator according to claim 1. wherein the adhesive film (142) comprises a plastic film (144) and an adhesive layer (148).

10. An inflator according to claim 9, wherein the plastic film (144) is made of the same material as the plastic base (116),

11. An inflator according to claim 10, wherein the plastic film (144) is made of a material which is suited for establishing a connection with the material of the plastic base (116).

12. An inflator according to claim 10, wherein the adhesive of the adhesive layer (146) can be activated by a predetermined contact pressure or thermal influence.

13. An inflator according to claim 10, wherein the materials of the plastic film (144) and the plastic base (116) are selected such that during injection-molding the plastic base (116) the plastic film (144) at least partially melts with the plastic base (116).

14. An inflator according to claim 10, wherein the adhesive film (142), especially the adhesive layer (146), forms a bonding bridge between the first component (112) and the plastic base (116),

15. An inflator according to claim 14, wherein the bonding bridge is plastically and/or elastically deformable.

16. An inflator according to claim 9, wherein the plastic film (144) includes a thermoplastic elastomer.

17. A method for manufacturing an inflator (10)s especially for a vehicle occupant restraint system, comprising the steps of: providing a first component (112) containing metal and/or plastic material and/or ceramic material, providing a second component (114) to be connected to the first component (112), applying an adhesive film (142) to the first component (112) in a connecting area, positioning the second component (114) relative to the first component (112), and jointly surrounding at least partially the first and second components (112,114) by injection molding, thereby forming a plastic base (116) connecting the components (112, 114),

18. A method according to claim 17, wherein a plastic film (144) of the adhesive film (142) melts with the plastic base (116) during injection molding.

19. A method according to claim 17, wherein during or after applying the adhesive film (142) the adhesive of the adhesive film (142) is activated by pressing or beating.

20. A module comprising an inflator (10,110), an airbag (96) inflatable by the inflator (10, 110) and a fastening means for attaching the module, especially in the interior of a vehicle, wherein the inflator (10, 110) is formed according to claim 17.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0130] FIG. 1 shows a sectional view of an inflator according to the invention;

[0131] FIG. 2 is a detailed view of FIG. 1;

[0132] FIG. 3 is another detailed view of FIG. 1;

[0133] FIG. 4a is a schematic plan view of the flange of an inflator according to the invention;

[0134] FIG. 4b illustrates a variant of the flange shown in FIG. 4a;

[0135] FIGS. 5 and 6 show schematic perspective views of an airbag supporting sheet of a module according to the invention, especially an airbag module, comprising a mounted inflator according to the invention;

[0136] FIG. 7 is a schematic cross-sectional view of an airbag module according to the invention comprising an inflator according to the invention;

[0137] FIG. 8 is a schematic perspective representation of a diffuser of an inflator according to the invention;

[0138] FIG. 9 is a schematic sectional view of the diffuser shown in FIG. 8,

[0139] FIG. 10 is a sectional view of an inflator according to the invention;

[0140] FIG. 11 is an enlarged detail of FIG. 10 showing the connection of a first and a second component; and

[0141] FIG. 12 is an enlarged illustration of the transition from the first to the second component.

[0142] FIG. 1 shows an inflator 10 comprising an external housing 12 being composed of a cup-shaped diffuser 14 having a substantially cylindrical circumferential wall 16 and a closing member 18 which also forms the bottom of the inflator 10.

[0143] The closing member 18 includes a circumferential upright edge 20 which is adjacent to the inside of the circumferential wall 16 of the diffuser 14 and is fixedly connected to the same by way of a weld 22. The weld 22 preferably extends along the entire contact surface between the closing shell 18 and the diffuser 14 and to the outside of the inflator 10, where it fills a groove existing between the closing member 18 and the diffuser 14. For connecting the diffuser 14 and the closing member 18 a laser welding method can be used, for instance.

[0144] At the closing member side end, the circumferential wall 16 of the diffuser 14 is bent outwardly so that a planar flange 24 being horizontally circumferential along the inflator 10 is formed.

[0145] The closing member 18 has a central orifice 26 which serves for receiving a pre-fabricated igniter 28. The closing member 18 has a recess 34 including an annular portion 30 toward the central orifice 26. The recess 34 is sort of an inversion of the external housing. This area of the inflator 10 is illustrated in detail in FIGS. 2 and 3.

[0146] The igniter 28 is enclosed by a base 32 connecting the igniter 28 also to the closing member 18 and especially to the edge of the orifice 28 and the annular portion 30.

[0147] The base 32 consists of plastic material and is injection-molded after introducing the igniter 28 into the orifice 26. During injection-molding the plastic material encloses both the major part of the igniter 28 and the edge of the orifice 26 and also completely fills the recess 34 formed by the annular portion 30 at the outside of the inflator 10 with the exception of an outwardly directed igniter plug receipt 38 into which the contact pins for an electric contacting of the igniter 28 protrude. The igniter 38 is simultaneously embedded in the base 32 during injection molding. The orifice 26 is completely closed by the base 32 and the igniter 23 and the recess 34 is so-to-speak lined by the base.

[0148] In this case the igniter 28 is enclosed by the base 32 so far that merely its upper side as well as a short upper portion of an igniter cap 38 are left open.

[0149] The igniter 28 preferably is a separate prefabricated component. The igniter cap 36 is either part of the prefabricated igniter 28 or a separate component placed onto the igniter 28.

[0150] The igniter cap 36 in this example consists of plastic material, namely of a plastic material similar to that of the base 32, preferably of an identical plastic material. A standard material having a share of glass fiber is preferably used, wherein the glass fiber share may be, for instance, 30% by weight. The use of a similar or identical plastic material entails the fact that during injection-molding the igniter cap 38 melts completely or partly with the base 32 and in this way a tight and non-detachable connection is formed.

[0151] The recess 34 can also be formed at a separate part of the inflator 10 which is connected to the external housing 12, especially to the dosing member 18.

[0152] At the outside of the recess 34 a circumferential indentation is formed between the closing member 18 and the base 32, which indentation is filled with a sealant 42, in this case in the form of an acrylate adhesive.

[0153] The sealant 42 is selected such that it adheres both to the metal of the closing shell 18 and to the plastic material of the base 32. The sealant 42 is applied from outside after injection molding of the base 32 and is located completely outside the external housing 12 of the inflator 10 and completely in the circumferential indentation,

[0154] The sealant 42 is applied in liquid or pasty form and is hardened by UV light. It has high flexibility also at low temperatures of up to −40° C. it features low viscosity so that it is easy to process, has good wetting properties both for metallic and for plastic surfaces and adheres both to metal and to plastic material.

[0155] The sealant has at least one of the following properties:

[0156] Breaking strength according to ISO 527 [MPa] 2-4, esp. 3;

[0157] Elongation at break according to ISO 527 [%] 200-400, esp. 300±40;

[0158] Viscosity at 23° C. according to Brookfield Sp/U and 3/100 [mPas]400-800, esp. 600±80;

[0159] Glass transition temperature (rheometer) [° C.] 10-30, esp. 20±4;

[0160] Thermal expansion coefficient at 30-140° C. [ppm/K] 150-350, esp. 260±30;

[0161] Density at 23° C. [g/cm3] 0.6-1.5, esp. 1.0±0.1;

[0162] Wafer absorption according to ISO 62, 24 h at 23° C. [%] 0.9-1.7 esp. 1.3±0.2.

[0163] A dye, preferably a fluorescent dye, is added to the sealant 42. This permits simple control whether the sealing bead has been completely applied and the recess is completely filled with the sealant 42. When irradiated with UV light, it can be easily recognized due to the fluorescent dye at which position the sealant 42 is provided. If a non-fluorescent dye is used, for the same a color other than for the base 32 and the closing member 18 is chosen so that it can be recognized by way of the color whether the sealing bead is complete and circumferential.

[0164] This can be checked using a camera.

[0165] Prior to mounting into an airbag module, the contact pins 40 of the inflator 10 are connected via a short-circuit bridge 44. The igniter plug receipt 38, the base 32 and the sealant 42 are covered in this state by a laminate film 46 and are protected against environmental influences in this way.

[0166] The wall forming the recess 34 is arc-shaped in portions in the radial direction r (cf. FIG. 3) in such a manner that one or more bulges 43 extending in radial direction away from the recess 34 are formed. The inflator 10 has a central axis A (cf. FIG. 1), Relative to this central axis A the arc forming the bulge 48 in this example extends in ring shape around the recess 34.

[0167] It is also possible to form the bulge 43 in circumferential direction intermittently and to provide only one or more separate bulges 48 along the circumference of the recess 34. The extension of the wall is shown in broken lines in FIG. 3. The wall thickness of the wall of the recess 34 is unchanged in this case vis-à-vis the wall thickness outside the bulge 48.

[0168] In the section shown in FIG. 3 the wall of the recess 34 forms an S-shaped curve in the area of a bulge 46, the opening portion (lower axial end) of the wall forming the recess 34 extending outwardly.

[0169] Apart from the annular portion 30, the recess 34 includes a bottom portion 50 which is connected to the annular portion 30 toward the interior of the inflator 10. The bottom portion 50 also forms the edge of the orifice 26. At the bottom portion 50 an annularly circumferential projection 52 is formed at the edge of the orifice 26 toward the outside of the inflator (provided with reference numerals only in FIG. 3). The projection 52 forms a convex shape and is shaped without any sharp edges. On the opposed side (inner side) the bottom portion has an indentation preferably rectangular in profile which extends equally circumferentially along the edge of the orifice 26 and whose orifice is directed toward the interior of the inflator 10.

[0170] Both the groove 54 and the projection 62 are enclosed by liquid plastic material when the base 32 is injection-molded so that a fast and tight connection to the base 32 is formed which also withstands temperature variations and constitutes an additional support during and after solidification of the plastic material Also the groove 54 is shown with reference numeral in FIG. 3 only.

[0171] Inside the external housing 12 an annular, thus substantially toroidal combustion chamber 56 is formed (cf. FIG. 1) which is filled with a known pyrotechnic gas-generating agent 58, indicated by some tablets in this case.

[0172] Toward the central axis A of the inflator 10, the combustion chamber 66 is confined by a cap 60 enclosing the igniter 28 and the portion of the base 32 located inside the inflator 10 as well as in addition a tree space in the form of an intermediate chamber 62. The intermediate chamber 62 is filled with a boosting charge of known pyrotechnic gas-generating material 64.

[0173] The cap 60 (cf. FIG. 2) has plural overflow orifices 66 providing a communication between the intermediate chamber 62 and the combustion chamber 56. In this example, the cap 60 is made of steel. It is closed at the upper end and open at the lower end and has a substantially cylindrical wall in which the overflow orifices 66 are disposed. The cap 60 is outwardly bent at the open end so that a short flange 66 is formed (cf. FIG. 2). After introducing the boosting charge 64, the cap 60 is merely pushed onto the base 32 and is possibly pressed with the same or pushed onto the same forming a press-fit. Fastening by welding is not provided. This leads to the fact that, when activating the inflator 10 and igniting the igniter 28, the cap 60 can move in the upward direction, i.e. away from the igniter 28. In this way, in the course of the burning operation also the overflow orifices 66 move upwards, i.e. relative to the propellant Thus further portions of the propellant bed in the combustion chamber 56 contact the hot gases flowing out of the intermediate chamber 62 and are ignited.

[0174] The upper portion of the combustion chamber 56 in FIG. 1, viz. at the side of the external housing 12 opposed to the igniter 28, is provided with an elastic component 70, in this case a filler or volume compensating element which contacts the upper side of the diffuser 14. The elastic component 70 is formed of a wire mesh here and can be compressed when the cap 60 moves. Further moving space for the cap 60 is gained from the bulge of the inflator 10 during gas formation during which the upper side of the diffuser 14 is slightly raised.

[0175] The elastic component 70 has a central recess 72 into which the cap protrudes up to a step and whose upper end portion is somewhat smaller than the diameter of the cap 60 in order to counter the movement of the cap 60 by a defined moving resistance.

[0176] In this case the cap 60 constitutes the only partition wall between the intermediate chamber 62 and the combustion chamber 66. It is possible that the inside of the cap 60 is lined with a protective film 74 closing the overflow orifices 66 prior to activation of the inflator 10, wherein the protective film 74 is destroyed upon ignition of the igniter 28.

[0177] In the state before activation shown in FIG. 1, the overflow orifices 66 are located directly at the upper edge of the base 32 so that they have an as large moving distance as possible in the direction of the central axis A.

[0178] A filter 76 is arranged in the combustion chamber 56 which in this case is ring-shaped, substantially cylindrical and extends in parallel to the circumferential wall 16 of the diffuser 14 at a small radial distance from the same.

[0179] The filter 76 extends over the entire height of the inflator 10 and extends from the closing member 18 to the end face of the diffuser 14. The filter 76 is formed of a wire mesh including wires of different thickness.

[0180] In the circumferential wall 16 of the diffuser 14 plural, in this example twelve, discharge orifices 78 are formed which are uniformly spaced along the circumference of the diffuser 14 and are arranged at an axial height. The filter 76 separates the discharge orifices 78 from the combustion chamber 56 so that the filter 78 is located upstream of the discharge orifices 78.

[0181] The filter 76 is pressed into the external housing 12 with axial pre-tension.

[0182] The filter 76 includes two axial ends 80, 82 at least one end of which is bent outwardly. In this case the bent portion forms the lower axial end 30 and the bending extends straight, in the bent portion the filter 76 has the same thickness as it has also in a central portion which is adjacent to the bent portion.

[0183] In the shown example the filter 76 extends in S-shape viewed in an axial section. At the upper axial end 82, too, a slight bending is provided which extends toward the center of the inflator 10, however (indicated on the left half in FIG. 1 by broken lines).

[0184] At the filter 76 the radially innermost contacting position of the outwardly bent lower axial end 80 is located radially further outward than the radially outermost contacting position of the inwardly bent axial end 82 so that the end-face contact surfaces are laterally completely offset.

[0185] The bent portion at the lower axial end 80 is adjacent to a corner formed by the housing of the inflator 10. In this case the housing part is formed by the closing member 18 and the lower axial end 80 of the filter 76 is adjacent to the transition from a bottom plate of the closing member 18 to the upwardly bent edge 20 of the same.

[0186] At the upper axial end 82 the filter 78 is tapered, as is visible especially on the right side of FIG. 1. At this end, the filter 76 has a larger length of thin wires, relative to the volume, than in the adjacent area and preferably than in the residual filter, which renders the tapered area very flexible.

[0187] This shaping permits to deform the material during axial pressing into the inflator such that no bypass is formed for particles possibly occurring during combustion of the pyrotechnic material 58.

[0188] The pyrotechnic material 58 in the combustion chamber 56 is surrounded with metal on all sides, i.e. the combustion chamber wall composed of several parts consists throughout of the same material. The combustion chamber 56 is enclosed by the elastic filler 70, the filter 76, the cap 60 and the closing member 80. As stated before, all these components preferably consist of the same metal, preferred of the same steel.

[0189] The discharge orifices 78 are closed prior to activation of the inflator 10 by a tamping 84 in the form of a tamping film. The tamping 84 is disposed circumferentially at the inside of the circumferential wall 16 of the diffuser 14 at the height of the discharge orifices 78 and covers all discharge orifices 78. The height of tamping 84 is approximately four times the diameter of the discharge orifices 78 in this case.

[0190] The lower end of the tamping 84, viz. the end facing the closing member 18, is arranged at a distance from the weld 22 which connects the diffuser 14 to the closing member 18. The distance a from the weld 22, or in this case equivalent to the end of the upper edge 20 of the closing member 18, in the shown case amounts to approx. 5.5 mm and preferably ranges from 3 to 7 mm (cf. FIG. 1). This distance is sufficient to prevent undesired heat transfer to the tamping 84 during welding.

[0191] The external housing 12 of the inflator 10 has a relatively thin wall thickness which in the example shown here nowhere is more than 2 mm. In particular, the wall thickness of the diffuser is 1.5 mm and that of the closing member is 1.9 mm. These wall thicknesses are sufficient to withstand a combustion chamber pressure of 300 bars upon activation of the inflator 10.

[0192] The diffuser 14 and the closing member 18 are connected only through the weld 22 so that said weld 22 forms the only connection between the components of the external housing 12 defining the strength. Preferably a tension rod is not provided.

[0193] In this case, the ratio of the maximum combustion chamber pressure to the wall thickness preferably is between 150 and 220 bars/mm.

[0194] The ratio of the entire discharge area of the inflator 10, viz. the sum of the areas of all discharge orifices 78, to the wall thickness is more than 30, especially more than 34 mm, in this case.

[0195] The ratio of the diameter D of the diffuser, measured by the diameter of the circumferential wall 18, to the minimum wall thickness of the external housing is preferably less than 50 and preferably ranges from 35 to 45. The flange 24 is not taken into account when determining the diameter.

[0196] The inflator 10 has substantially the shape of a flat cylinder, the ratio of the diameter D to the maximum axial height H being approx. 1.8±0.2, preferably 1.8±0.1.

[0197] The flange 24 at the outer circumference of the diffuser 14 is planar but unsymmetrical (cf. FIGS. 4a and b). This design offers a positioning aid when mounting the inflator 10 into a module, for instance an airbag module, by clearly defining the mounting position.

[0198] In the present example three notches are spaced along the circumference of the flange 24 as mounting positioning means 88s namely at different angular distances. The angles between the notches amount for instance, to 115 and 148° or to 93 and 109° in a different example.

[0199] As an additional or alternative mounting positioning means an orifice 88 is formed as oblong hole in the flange 84. This orifice 88 is the only orifice provided in the flange 84.

[0200] As a matter of course, also more or fewer notches 86 or projections instead of the notches or other suitable mounting positioning means 86 can be provided.

[0201] When mounting the inflator 10 into a module, for instance an airbag module 90 shown in FIG. 7, the inflator 10 is fastened by a clamping or holding element 92 (cf. also FIGS. 6 to 7). The holding element 92 has a central opening through which the inflator 10 partly extends so that the holding element 92 presses against the flange 24. The holding element 92 includes corresponding mounting positioning means 94 which are complementary to the mounting positioning means 86 of the flange 24 of the inflator 10. In this case, the mounting positioning means 94 are formed by integrally provided projections in the holding element 92, for instance in the form of cut-out and upwardly bent sheet sections. The projections engage in the notches and thus clearly define the mounting position of the inflator 10.

[0202] The orifice 88 in the flange 24 serves for defining the mounting position of an airbag 96 (indicated in FIG. 7) which is clamped between the flange 24 and the holding element 92 by the orifice edge 100 of its injecting orifice 98.

[0203] The oblong hole 88 moreover can also be used for manufacturing the inflator. In particular, in different manufacturing steps the correct position of the diffuser (flange) with respect to other inflator components can be ensured by a pin in the tool head which is adapted to be engaged with the oblong hole, e.g. for orientation of the igniter pins.

[0204] The airbag 96 likewise has an orifice at the orifice edge 100 (not shown) which is made to match with the orifice 88 in the flange in order to correctly position the airbag 96. The orifice 88 does not serve as screwing orifice and constitutes the only orifice at the orifice edge 100 of the airbag 96, This means that the airbag 96 is clamped between the flange 24 and the holding element 92 by fastening means, usually stud bolts, which are located outside the flange 24. Thus the flange surface is optimized.

[0205] For fastening the airbag module 90 the holding element 92 includes fastening bolts 102, four of them in the shown example, through which the airbag module 90 can be connected to a vehicle (not shown). The fastening bolts 102 are adjacent to the outer circumference of the flange 24 but offside the area of the mounting positioning means 86.

[0206] The flange 24 is circumferential and planar.

[0207] It forms an annular clamping surface for the airbag 96, wherein the width B of the flange (the transition radius between the planar flange portion and the circumferential wall of the diffuser 14) is between 5 and 12%, preferably between 8 and 11% of the maximum diameter D of the external housing 12.

[0208] The width B of the clamping surface in the radial direction r ranges from 5 to 8.5, preferably from 5.5 to 7.5 mm (cf. FIG. 9).

[0209] At the holding element 92 opposed to the clamping surface a clamping portion 104 is defined at the flange 24 (cf. FIG. 7), which clamping portion produces a holding force for the airbag 96 together with the clamping surface at the flange 24. The clamping surface and the clamping portion 104 are designed such that the forces acting via the maximum internal pressure in the airbag 96 on the orifice edge 100 are by 20 to 50% less than the clamping force produced between the clamping surface and the clamping element 104. The width B of the flange 24 can be considerably reduced, so-to-speak to the minimum flange width, by this very simple measure.

[0210] FIG. 10 shows a special embodiment of an inflator 110 according to the invention which exhibits a first component 112, here made of metal, in the form of an inflator housing in which an igniter device 113 is centrally disposed. The latter comprises an igniter constituting a second component 114 which is connected to the first component 112 via an injection-molded plastic base 116 by the fact that both components are at least partly jointly surrounded by injection-molding. The igniter in this case is a prefabricated component enclosed by a metallic outer shell and includes plural connecting wires 118 partly embedded in the plastic base 116 which project through an orifice 120 in the first component 112 (the inflator housing) from the latter. The orifice 120 simultaneously serves for receiving and fastening the second component 114 (of the igniter), wherein especially the portion of the first component 112 forming the edge 122 of the orifice 120 is embedded in the plastic base 116 during injection-molding.

[0211] The upper end of the igniter in FIG. 10 is adjacent to a booster chamber 124 filled with a boosting charge. In the shown configuration a sleeve 126 confining the booster chamber 124 and having plural overflow orifices 128 is placed onto the igniter or the plastic base 116. The booster chamber 124 is surrounded by a combustion chamber 130 which is filled with a schematically illustrated propellant 132 in the form of tablets and at the outside is adjacent to a filter 134. At its circumferential wall, the inflator housing has discharge orifices 136 which in the mounted state are protected against penetration of moisture by a tamping film 138. Upon activation of the inflator 110, a gas is generated in a known way which flows to the outside through the discharge orifices 136 and serves, e.g., for filling an airbag of a vehicle occupant restraint system.

[0212] In the contacting area 140 located in the vicinity of the orifice 120 or the edge 122 between the plastic base 116 and the first component 112, the latter is provided with an adhesive film 142 which was applied already before injection-molding the plastic base 116. The adhesive film 142 only covers a portion of the injection-molded area of the first component 112. The adhesive film 142 is folly circumferential around the edge 122, however.

[0213] The adhesive film 142 is a pre-fabricated component and consists of a plastic film 144 and an adhesive layer 146 directly and evenly applied thereto (cf. FIG. 12).

[0214] The material used for the plastic film 144 in this example is the same material as used for the plastic base 116, it is also possible, however, to use a different material which is suited for establishing a tight connection with the material of the plastic base 116. This can be a thermoplastic elastomer, for instance.

[0215] The adhesive film 142 serves as a bonding bridge between the plastic base 116 and the first component 112.

[0216] Deviating from the illustrated configuration, the surface of the adhesive film 142 can also extend over the entire injection-molded portion of the component 112 or project from the same, as a matter of course. it is also possible to provide an appropriate adhesive film also between the second component 114 and the plastic base 116.

[0217] The inflator 110 is manufactured as follows: To start with, the first component 112 (the inflator housing) as well as the second component 114 (the igniter) are provided and the first component 112 is provided with the adhesive film 124 in the later connecting area of the components (corresponding to the contacting area 140) by gluing one or more appropriately cut pieces of the adhesive film 142 with the adhesive layer 146 onto the corresponding positions of the first component 112, in this case on both sides in the area of the edge 122.

[0218] The adhesive of the adhesive layer 146 can be activated or hardened already now by the pressure during gluing. Alternatively, it is activated or hardened by heating, which is effectuated e.g. during injection-molding by the heat influence of the liquid plastic material.

[0219] After the adhesive film 142 was glued onto the first component 112, the second component 114 is positioned relative to the first component 112, and both components 112, 114 are jointly surrounded by injection-molded forming the plastic base 116, wherein both components 112, 114 are embedded at least partly in the plastic base 116.

[0220] During injection-molding the material of the plastic film 144 combines with the injected plastic material by the fact that a surface layer of the plastic film 144 melts in a connecting zone 148 with the plastic base 118. As an alternative, in the connecting zone 148 also e chemical reaction can take place between the material of the plastic film 144 and that of the plastic base 116, which reaction tightly and non-detachably interconnects the plastic film 144 and the plastic base.

[0221] The adhesive layer 146 forms a bonding bridge between the first component 112 and the plastic base 116, the bonding bridge being resilient and/or plastically deformable so that tensions and shear forces occurring due to different thermal expansion coefficients of the different materials are compensated. The adhesive layer 146 also acts as a packing between the first component 112 and the plastic base 116.

[0222] All described features can be combined with or exchanged for one another at the discretion of those skilled in the art.