Waveguide sensor assemblies and related methods

Abstract

Methods for manufacturing a vehicle sensor module, such as a RADAR sensor module. In some implementations, the method may comprise forming a sub-assembly comprising a plurality of stacked layers formed into a self-contained radome and adhering the sub-assembly to a first side of an antenna block, the first side comprising a plurality of waveguide grooves formed therein. The sub-assembly may be applied so as to provide a weatherproof seal to each of the plurality of waveguide grooves formed in the antenna block. A PCB layer may be applied to a second side of the antenna block opposite the first side and the antenna block may be seated within a cover such that the second side is protected by the cover and the first side is protected by the self-contained radome.

1 . A method for manufacturing a vehicle sensor module, the method comprising the steps of:
 forming a sub-assembly comprising a plurality of stacked layers formed into a self-contained radome;   adhering the sub-assembly to a first side of an antenna block, the first side comprising a plurality of waveguide grooves formed therein, such that the sub-assembly provides a weatherproof seal to each of the plurality of waveguide grooves formed in the antenna block;   coupling a PCB layer to a second side of the antenna block opposite the first side; and   seating the antenna block within a cover such that the second side is protected by the cover and the first side is protected by the self-contained radome.   
     
     
         2 . The method of  claim 1 , wherein the cover comprises a closed bottom and an open top. 
     
     
         3 . The method of  claim 2 , wherein the step of seating the antenna block within the cover comprises coupling the cover to the antenna block such that the second side of the antenna block is recessed within the cover adjacent to the closed bottom. 
     
     
         4 . The method of  claim 1 , wherein the step of seating the antenna block within the cover comprises crimping the cover to the antenna block. 
     
     
         5 . The method of  claim 4 , wherein the antenna block further comprises a recess, and wherein the step of crimping the cover to the antenna block comprises crimping the cover to the antenna block within the recess. 
     
     
         6 . The method of  claim 1 , wherein the self-contained radome comprises three layers. 
     
     
         7 . The method of  claim 6 , wherein one of the three layers comprises an adhesive film. 
     
     
         8 . The method of  claim 7 , wherein one of the three layers comprises a conductive layer. 
     
     
         9 . The method of  claim 8 , wherein the conductive layer comprises a plurality of openings, and wherein each of the plurality of openings is aligned with a corresponding waveguide groove of the plurality of waveguide grooves. 
     
     
         10 . The method of  claim 8 , wherein one of the three layers comprises a slotted layer comprising a plurality of slots configured to receive electromagnetic signals therethrough, and wherein each of the plurality of slots is aligned with a corresponding waveguide groove of the plurality of waveguide grooves. 
     
     
         11 . The method of  claim 6 , wherein each of the three layers is flexible such that the entire self-contained radome is flexible. 
     
     
         12 . The method of  claim 1 , wherein the antenna block further comprises at least one mounting tab configured for mounting the vehicle sensor module to a vehicle. 
     
     
         13 . The method of  claim 12 , wherein the step of crimping the cover to the antenna block within the recess is performed such that the at least one mounting tab protrudes beyond a perimeter of the cover. 
     
     
         14 . The method of  claim 12 , wherein the at least one mounting tab protrudes beyond a perimeter of both the antenna block and the self-contained radome. 
     
     
         15 . The method of  claim 1 , wherein the antenna block comprises a second plurality of waveguide grooves formed on the second side. 
     
     
         16 . The method of  claim 15 , further comprising applying an adhesive layer to the second side of the antenna block. 
     
     
         17 . The method of  claim 16 , wherein the adhesive layer applied to the second side comprises a plurality of openings, and wherein each opening of the plurality of openings of the adhesive layer on the second side is aligned with a corresponding waveguide groove of the plurality of waveguide grooves formed on the second side.