Automotive radar sensor packaging methods and related assemblies

1. A vehicle sensor assembly, comprising:

a housing;

a printed circuit board coupled to the housing, the printed circuit board comprising a first side and a second side opposite the first side;

an integrated circuit positioned on the first side of the printed circuit board;

one or more antennas operably coupled with the integrated circuit; and

a flexible radome fully enclosing the assembly about an entire perimeter of the assembly.

2. The vehicle sensor assembly of claim 1 , wherein the flexible radome comprises a thermoplastic wrapper, and wherein the thermoplastic wrapper is configured to bind the printed circuit board to the housing.

3. The vehicle sensor assembly of claim 2 , wherein the thermoplastic wrapper comprises a tube positioned over the assembly and sealed at opposing ends thereof.

4. The vehicle sensor assembly of claim 2 , wherein the thermoplastic wrapper comprises opposing thermoplastic sheets sealed about their respective perimeters to enclose the assembly.

5. The vehicle sensor assembly of claim 1 , further comprising a metallic shield coupled with the housing, the metallic shield being configured to provide electromagnetic interference shielding to the integrated circuit, wherein the metallic shield comprises an integral part of the housing.

6. The vehicle sensor assembly of claim 1 , further comprising a microprocessor positioned on the first side of the printed circuit board.

7. The vehicle sensor assembly of claim 1 , wherein the vehicle sensor assembly comprises a RADAR sensor assembly.

8. The vehicle sensor assembly of claim 1 , wherein the integrated circuit is thermally coupled to the housing.

9. The vehicle sensor assembly of claim 8 , further comprising a thermal coupling element positioned within the metallic shield and coupled with the integrated circuit.

10. The vehicle sensor assembly of claim 1 , wherein each of the one or more antennas is positioned at the second side of the printed circuit board.

11. The vehicle sensor assembly of claim 1 , wherein each of the one or more antennas comprises slot antennas.

12. The vehicle sensor assembly of claim 1 , wherein the printed circuit board lacks any projecting electrical components on the second side.

13. A vehicle sensor assembly, comprising:

a housing defining a plurality of waveguides, wherein each waveguide of the plurality of waveguides is defined by a waveguide groove;

a printed circuit board coupled with the housing to define an enclosure between the housing and the printed circuit board, the printed circuit board comprising a first side and a second side opposite the first side;

an integrated circuit positioned on the first side of the printed circuit board;

an antenna structure operably coupled with plurality of waveguides, wherein the antenna structure comprises an array of one or more slots extending along an axis of each waveguide groove of the plurality of waveguides, and wherein each of the one or more slots is configured to deliver electromagnetic radiation from at least one of the plurality of waveguides therethrough; and

a flexible radome fully enclosing the enclosure defined by the housing and the printed circuit board.

14. The vehicle sensor assembly of claim 13 , wherein the flexible radome comprises a thermoplastic wrapper.

15. The vehicle sensor assembly of claim 13 , wherein the housing further comprises a hub, and wherein the hub comprises a thermal coupling pad configured to contact the integrated circuit.

16. The vehicle sensor assembly of claim 15 , wherein the housing comprises a domed structure, wherein the thermal coupling pad is positioned on the domed structure.

17. The vehicle sensor assembly of claim 13 , further comprising a metallic shield coupled with the housing, the metallic shield being configured to provide electromagnetic interference shielding to the integrated circuit.

18. A method for assembling a vehicle sensor assembly, the method comprising the steps of:

forming a metallic shield on a housing;

coupling a printed circuit board to the housing, the printed circuit board having a first side and a second side opposite the first side, wherein the printed circuit board is coupled to the housing such that the first side faces the housing, wherein the printed circuit board comprises an integrated circuit positioned on the first side of the printed circuit board, and wherein the printed circuit board is coupled to the housing such that the integrated circuit is positioned within the metallic shield to provide electromagnetic interference shielding to the integrated circuit; and

sealing a flexible thermoplastic wrapper about an entire perimeter of the thermoplastic wrapper to fully enclose the housing and the printed circuit board.

19. The method of claim 18 , wherein the step of forming the metallic shield comprises forming a metallic fence about a thermal coupling pad, and wherein the step of coupling the printed circuit board to the housing comprises contacting the integrated circuit with the thermal coupling pad.

20. The method of claim 19 , wherein the housing further comprises a projecting member positioned within the metallic fence to facilitate contact between the integrated circuit and the thermal coupling pad.

21. The method of claim 18 , wherein the step of sealing a flexible thermoplastic wrapper about the housing and the printed circuit board comprises:

inserting the housing coupled with the printed circuit board into a thermoplastic tube; and

heat sealing opposing edges of the thermoplastic tube.

22. The method of claim 18 , wherein the printed circuit board comprises one or more antennas, and wherein each of the one or more antennas is positioned along the second side of the printed circuit board.