Waveguide antenna sensor component for a radar sensor

Abstract

The invention discloses a method for producing a waveguide antenna sensor component (100) for a radar sensor. The method comprises providing a waveguide antenna (102) in the form of a metallized plastics waveguide antenna (100) and producing a sensor housing (120), which surrounds the waveguide antenna (102), from plastic by means of injection moulding. The sensor housing (102) encompasses an edge portion (108) of the waveguide antenna (102) and has a front panel (122), which encloses a metallized front portion (106) of the waveguide antenna (102).

Description

Waveguide antenna sensor component for a radar sensor FIELD OF TECHNOLOGY

[0001] The invention relates to the field of waveguide antennas, more specifically to a method for producing a waveguide antenna sensor component for a radar sensor and a waveguide antenna sensor component for a radar sensor. STATE OF THE ART

[0002] Waveguide antennas are used in a wide variety of applications, such as radar sensors and communications systems. They exhibit, for example, a lower standard deviation in their performance (i.e., gain and phase) than typical microstrip antennas. They are also flatter and therefore easier to integrate into devices than typical horn antennas.

[0003] It is an object of the invention to provide a method for producing an improved waveguide antenna sensor component for a radar sensor, as well as an improved waveguide antenna sensor component for a radar sensor. The objects underlying the invention are achieved by the features of the independent claims. SUMMARY

[0004] In one aspect, a method for manufacturing a waveguide antenna sensor component for a radar sensor is disclosed, which comprises providing a waveguide antenna in the form of a metallized plastic waveguide antenna and producing a plastic sensor housing enclosing the waveguide antenna by injection molding. The sensor housing surrounds an edge portion of the waveguide antenna and has a front panel that frames a metallized front portion of the waveguide antenna.

[0005] Using a front panel or integrating the waveguide antenna sensor component into the front panel can have the advantage that the size of the waveguide antenna or the material to be metallized can be tailored solely to its function as an antenna. Size differences between the waveguide antenna and the free space in which the waveguide antenna is to be inserted or installed can be compensated for by the front panel. For example, a gap resulting from the size differences can be bridged. Such a free space is usually designed to accommodate all the components necessary for operation, including additional electronic components. Therefore, such a free space will generally be larger than a waveguide antenna, whose size is designed solely for its function as a pure antenna.

[0006] By using the front panel, it is possible to avoid having to artificially enlarge the waveguide antenna beyond the size necessary for its pure function as an antenna, in order to be able to securely install the waveguide antenna in the designated free space. This allows for material savings for the waveguide antenna. In particular, metal can be saved. The smaller the waveguide antenna, the less material needs to be metallized, for example.

[0007] This article describes an approach for combining or fusing a metallized plastic waveguide antenna with a modified sensor housing using injection molding to form a single unit that functions both as an antenna and a housing. With this solution, the metallized plastic waveguide antenna only needs to be the size required for its function as an antenna. However, it is still part of the sensor housing, into which it is incorporated or integrated using injection molding.

[0008] The additional material required in this case to form the sensor housing, in particular the front panel, consists of plastic, for example, which does not need to be metallized since it does not contribute to the antenna functionality, for example.

[0009] In addition, the sensor housing can, for example, include receptacles for electronic components. The sensor housing can provide protection for the corresponding electronic components. Furthermore, the sensor housing can, for example, include fastening elements for securing the sensor housing and thus the waveguide antenna, for example, in a vehicle. This can, for example, simplify the attachment of the waveguide antenna to a designated location.

[0010] The sensor housing serves, for example, to protect the waveguide antenna. Furthermore, the sensor housing serves, for example, to dissipate heat.

[0011] A metallized plastic waveguide antenna, for example, comprises two parts: a front part of the waveguide antenna, which comprises the front section, and a rear part, which are connected to each other and enclose an interior space with a waveguide structure. The two parts are manufactured from plastic using an injection molding process, metallized, and then soldered together. Alternatively, the two injection-molded parts can also be glued together and metallized. The result is, for example, a single part, which is referred to as a metallized plastic waveguide antenna.

[0012] Examples may have the advantage that such a metallized plastic waveguide antenna is inherently robust. By enclosing it in the sensor housing, the waveguide antenna is used as part of the sensor housing.

[0013] For example, the waveguide antenna sensor component is provided with electronics. The electronics can be configured, for example, to generate and process radio-frequency signals. For example, the electronics comprise a printed circuit board (PCB), a radio-frequency integrated circuit (RFIC), and / or a system-on-a-chip (SoC). The disenfranchising electronics can, for example, be arranged in a designated receptacle, in particular in a rear receptacle, of the sensor housing. In addition, electronic lines for connecting the electronics can be accommodated in the sensor housing.

[0014] The waveguide antenna can be configured, for example, for use in a vehicle's radar sensor. The waveguide antenna can be used, for example, for medium- to long-range radar applications in a vehicle, such as front, rear, and / or corner radar that can be used for adaptive cruise control (ACC) or parking assistance purposes. The waveguide antenna can be configured, for example, for short-range radar applications, such as blind spot monitoring, curb detection in parking assistance, or obstacle, pedestrian, and / or cyclist detection in a vehicle door opening warning system.

[0015] For example, the method further comprises producing the waveguide antenna. Manufacturing the waveguide antenna comprises providing a first part of the Waveguide antenna, which is a front part encompassing the front section The waveguide antenna is made of plastic, providing a second part of the waveguide antenna, which is a rear part of the waveguide antenna made of plastic, at least partially metallizing the first and second parts of the waveguide antenna, and connecting the first and second metallized parts of the waveguide antenna along a connecting line. The two parts enclose an interior of the waveguide antenna with a waveguide structure.

[0016] For example, manufacturing the waveguide antenna in two parts can have the advantage of making it easier to fabricate the internal waveguide structures. Furthermore, two-part manufacturing can simplify the metallization of the waveguide antenna, as the interior of the two parts is more easily accessible before joining.

[0017] For example, the first and second parts of the waveguide antenna are each made of plastic. For example, the first part and / or the second part of the waveguide antenna are manufactured using one of the following processes: injection molding, 3D printing, or machining.

[0018] For example, the first and second parts of the waveguide antenna are connected to each other by means of a material-to-material bond. For example, the material-to-material bond comprises one of the following types of connection: an adhesive bond, a soldered bond. A material-to-material bond ensures that the two parts are firmly connected to each other and that the connection does not adversely affect the radiation conduction through the waveguide structure in the interior of the waveguide antenna.

[0019] For example, the first and second parts of the waveguide antenna are connected to each other by means of the sensor housing, which encompasses the edge section of the waveguide antenna in which the connecting line extends.

[0020] The sensor housing encompassing the edge section of the waveguide antenna, which is formed, for example, by edge sections of the two parts of the waveguide antenna, can firmly fix the two edge sections of the two parts of the waveguide antenna relative to each other. In this way, the sensor housing can contribute to fixing the connection between the two parts of the waveguide antenna. For example, the sensor housing can support the material connection between the two parts through a positive connection. It would also be possible to connect the two parts exclusively using the sensor housing. By enclosing the edge section of the waveguide antenna For example, a corresponding solid, i.e. non-destructively detachable, form fit can be created between the two parts of the sensor housing.

[0021] For example, the sensor housing is in physical contact with the edge portion of the waveguide antenna. This allows a solid connection between the sensor housing and the waveguide antenna to be established by encapsulating the edge portion of the waveguide antenna with the material used to manufacture the sensor housing.

[0022] For example, the metallization of the first and second parts of the waveguide antenna is carried out using a selective coating process that removes the metallic coating from the contact areas of the two parts, which form the edge sections of the waveguide antenna. By removing the edge section, a strong bond can be achieved between the plastic of the edge section and the injection-molded plastic of the sensor housing.

[0023] For example, the first part of the waveguide antenna comprises at least one of the following geometric structures in a transition region adjacent to the edge section of the waveguide antenna: a step toward the edge section, a dam structure. The step can be configured, for example, as a vertical transition, a beveled transition, or a curved transition toward the edge section. A curved transition can, for example, be concavely or convexly curved. The dam structure can, for example, have vertically arranged side flanks, sloping side flanks, or curved side flanks. Curved side flanks can, for example, be concavely or convexly curved.

[0024] The geometric structure extends, for example, along the front side of the first part of the waveguide antenna along the edge of the first part and forms a closed curve. The geometric structure can have the advantage of effectively preventing material from overflowing onto the front side of the first part of the waveguide antenna, particularly onto the metallized front section, during injection molding of the sensor housing.

[0025] For example, the second part of the waveguide antenna comprises at least one of the following geometric structures in a transition region adjacent to the edge section of the waveguide antenna: a step towards the edge section, a dam structure. The step can be designed, for example, as a vertical transition, a beveled transition, or a curved transition towards the edge section. A curved transition can, for example, be concave or convex. The dam structure can, for example, have vertically arranged side flanks, sloping side flanks, or curved side flanks. Curved side flanks can, for example, be concave or convex.

[0026] The geometric structure extends, for example, along the edge of the second part of the waveguide antenna on the back side, forming a closed curve. The geometric structure can have the advantage of effectively preventing material from overflowing onto the back side of the second part of the waveguide antenna during injection molding of the sensor housing.

[0027] For example, the edge section of the waveguide antenna has one or more undercuts that enclose the sensor housing. Enclosing the undercuts ensures that the waveguide antenna cannot be detached from the sensor housing without damage and is thus firmly held in position by the sensor housing. For example, the undercut extends along the edge section of the waveguide antenna and forms a closed curve. The undercut can be designed, for example, with a vertical transition, a beveled transition, or a curved transition. A curved transition can, for example, be concave or convex.

[0028] For example, at least one of the one or more undercuts extends forward in a direction facing the front section of the waveguide antenna. For example, at least one of the one or more undercuts extends rearward in a direction away from the front section of the waveguide antenna. Thus, the undercuts can be encompassed by the sensor housing, for example, on both sides.

[0029] For example, the metallized front section of the waveguide antenna comprises a plurality of openings for radar radiation. Before the sensor housing is manufactured, a dielectric film covering the openings is arranged on the metallized front section of the waveguide antenna and extends beyond the metallized front section. The sensor housing extends over at least one edge of the dielectric film and contributes to securing the dielectric film to the metallized front section of the waveguide antenna.

[0030] The foil covers the openings and protects the interior of the waveguide antenna as well as any electronic components located behind the waveguide antenna from Environmental influences, particularly moisture. The film can be used to replace a conventional radome. By being fixed using injection molding, the film can be incorporated or integrated into the sensor housing, which in particular eliminates the need for a separate radome. In addition, the film can be fixed to the front section, for example, by gluing or laser welding. In the case of laser welding, the welding areas between the dielectric film and the front section are advantageously kept free of metal. This can be achieved, for example, by selectively coating the front section with metal. The dielectric film can be a polyester film, for example. For example, it is an adhesive film with silicone as the adhesive.

[0031] For example, the sensor housing further comprises one or more connecting elements for mechanically connecting the waveguide antenna sensor component to a receptacle of a vehicle provided for the waveguide antenna sensor component.

[0032] The one or more connecting elements are thus integrated, for example, by injection molding into the sensor housing and thus into the solid unit formed by the waveguide antenna and the sensor housing. For example, one or more of the connecting elements can each be designed as a plug for establishing a plug connection with an associated receptacle for a holder for the sensor or the sensor housing.

[0033] In a further aspect, a waveguide antenna sensor component for a radar sensor is disclosed. The waveguide antenna sensor component comprises a waveguide antenna in the form of a metallized plastic waveguide antenna, which is enclosed by a sensor housing made of plastic by injection molding. The sensor housing surrounds an edge section of the waveguide antenna and has a front panel that frames a metallized front section of the waveguide antenna.

[0034] It is understood that one or more of the aforementioned embodiments may be combined with one another, as long as the embodiments do not exclude one another. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] The following examples are explained in more detail using the drawings. They show:

[0036] Fig. 1 is a flowchart of an exemplary method for producing a Waveguide antenna sensor component,

[0037] Fig. 2 is a flowchart of an exemplary method for producing a Waveguide antennas,

[0038] Fig. 3 is a flowchart of an exemplary method for producing a Waveguide antennas,

[0039] Fig. 4 is a schematic diagram of a front view of an exemplary Waveguide antenna sensor component,

[0040] Fig. 5 is a schematic diagram of a side sectional view of the exemplary Waveguide antenna sensor component from Fig. 4,

[0041] Fig. 6 is a schematic diagram of a side sectional view of a Connection area between waveguide antennas and sensor housing,

[0042] Fig. 7A to 7D are schematic diagrams of exemplary transition regions,

[0043] Fig. 8A to 8D are schematic diagrams of exemplary transition regions,

[0044] Fig. 9A to 9D are schematic diagrams of exemplary undercuts,

[0045] Fig. 10 is a schematic diagram of a front view of an exemplary Waveguide antenna sensor component, and

[0046] Fig. 11 is a schematic diagram of a side sectional view of the exemplary Waveguide antenna sensor component from Fig. 10. DETAILED DESCRIPTION

[0047] In the following, similar elements are identified by the same reference numerals.

[0048] Fig. 1 shows an exemplary method for manufacturing a waveguide antenna sensor component for a radar sensor. The radar sensor is, for example, a radar sensor for a vehicle. The method comprises, in block 200, providing a waveguide antenna. The waveguide antenna is a metallized plastic waveguide antenna. For example, the metallized plastic waveguide antenna is used as prefabricated component provided. For example, the provision of the metallized plastic waveguide antenna comprises the metallized plastic waveguide antenna, for example according to one of the exemplary manufacturing methods outlined in Figs. 2 and 3 for manufacturing a waveguide antenna, more precisely a metallized plastic waveguide antenna. In block 202, a plastic sensor housing enclosing the waveguide antenna provided in block 200 is produced by injection molding. In this process, the waveguide antenna is overmolded so that the resulting sensor housing encompasses an edge section of the waveguide antenna and a front panel. This plastic front panel frames a metallized front section of the waveguide antenna.

[0049] Fig. 2 shows an exemplary method for producing a waveguide antenna, such as can be used, for example, in the method for producing a waveguide antenna sensor component for a radar sensor according to Fig. 1. In block 210, a first part of the waveguide antenna is provided. This first part of the waveguide antenna is, for example, a front part of the waveguide antenna made of plastic and comprising the front section. For example, the front part of the waveguide antenna is provided as a prefabricated component. For example, providing the front part of the waveguide antenna comprises producing the corresponding part using plastic. For example, injection molding, 3D printing, and / or machining is used as a manufacturing method for producing the front part of the waveguide antenna. In block 212, a second part of the waveguide antenna is provided.This second part of the waveguide antenna is a rear part of the waveguide antenna made of plastic. For example, the front part of the waveguide antenna is provided as a prefabricated component. For example, providing the rear part of the waveguide antenna involves manufacturing the corresponding part using plastic. For example, injection molding, 3D printing, and / or machining are used as manufacturing methods for producing the rear part of the waveguide antenna.

[0050] In block 214, the first and second parts of the waveguide antenna provided in blocks 210 and 212 are at least partially metallized. These two at least partially metallized parts are connected to each other along a connecting line in block 216. The two interconnected parts enclose an interior of the waveguide antenna with a waveguide structure. For example, the connection is made by means of a material-to-material connection, such as an adhesive connection using an adhesive or a solder connection using a solder. Optionally, For example, the connection of the two parts of the waveguide antenna can be followed by further metallization, particularly of external surfaces such as the metallized front section of the waveguide antenna.

[0051] Fig. 3 shows a further exemplary method for producing a waveguide antenna, such as can be used, for example, in the method for producing a waveguide antenna sensor component for a radar sensor according to Fig. 1. In block 210, a first part of the waveguide antenna is provided. This first part of the waveguide antenna is, for example, a front part of the waveguide antenna made of plastic and comprising the front section. For example, the front part of the waveguide antenna is provided as a prefabricated component. For example, providing the front part of the waveguide antenna comprises producing the corresponding part using plastic. For example, injection molding, 3D printing, and / or machining is used as a manufacturing method for producing the front part of the waveguide antenna. In block 212, a second part of the waveguide antenna is provided.This second part of the waveguide antenna is a rear part of the waveguide antenna made of plastic. For example, the front part of the waveguide antenna is provided as a prefabricated component. For example, providing the rear part of the waveguide antenna involves manufacturing the corresponding part using plastic. For example, injection molding, 3D printing, and / or machining are used as manufacturing methods for producing the rear part of the waveguide antenna.

[0052] In block 216, these two parts are connected to each other along a connecting line. The two connected parts enclose an interior of the waveguide antenna with a waveguide structure. For example, the connection is made by means of a material-to-material bond, such as an adhesive bond using an adhesive. In block 218, the two connected parts of the waveguide antenna are then at least partially metallized.

[0053] Fig. 4 shows a front view of a waveguide antenna sensor component 100, which comprises a waveguide antenna 102 and a sensor housing 120. The waveguide antenna 102 is a metallized plastic waveguide antenna, which comprises a front side 104 facing forward, i.e. in the direction of radiation, with a metallized front section 106, i.e. a metallized radiation surface. The metallized plastic waveguide antenna 102 is enclosed by the sensor housing 120, which is made of plastic by injection molding. The sensor housing 120 encompasses an edge section 108 of the waveguide antenna 120 and represents a front panel 122 framing the metallized front section 106 of the waveguide antenna 102.

[0054] By injection molding the sensor housing 120, so that the waveguide antenna 102 is laterally overmolded, the waveguide antenna 102 can be incorporated as an integral component into a front cover of the sensor. The front cover of the sensor is, for example, defined by the front side 104 of the waveguide antenna 102 and the front panel 122 provided by the sensor housing 120, which frames the metallized front section 106 of the front side 104 of the waveguide antenna 102. The waveguide antenna 102 is encapsulated by the injection molding, for example, in the remainder of the front cover provided by the sensor housing, which includes the front panel 122. The sensor housing 120, or the remainder of the front cover provided by the sensor housing 120 in the form of the front panel 122, is made of non-metallized plastic. The sensor housing 120 can, for example, also comprise one or more connecting elements 124. The front cover shown in Fig.The exemplary sensor housing 120 shown in Figure 4 comprises, for example, a connecting element 124, which is designed as a plug for establishing a plug connection with an associated receptacle for a holder for the sensor or for the sensor housing 120. To ensure a robust connection between the at least partially metallized plastic waveguide antenna 102 and the sensor housing 120, the connection area of ​​the waveguide antenna 102, i.e., the edge section 108, is not metallized. This can be achieved, for example, by selectively coating the waveguide antenna with metal, in which the edge section 108 is not metallized. This leads, for example, to good adhesion between the edge section 108 and the part of the sensor housing 120 in contact with the edge section 108.In addition, the edge section 108 can, for example, have an undercut, which is encapsulated by the surrounding injection molding material during the injection molding process and ensures a firm hold of the waveguide antenna 102 in the sensor housing.

[0055] Fig. 5 shows a side sectional view of the exemplary waveguide antenna sensor component 100 from Fig. 4. The waveguide antenna sensor component 100 comprises a sensor housing 120, which frames a waveguide antenna 102. The waveguide antenna 102 consists of two parts, ie a front part 112 and a rear part 114. The front part 112 of the waveguide antenna 102 comprises the front side 104 with the metallized front section 106 of the waveguide antenna 102. The rear part 114 comprises antenna feed elements 118, which are designed as waveguides and configured to High-frequency signals are to be fed to the waveguide antenna 102 for transmission, and high-frequency signals received by the waveguide antenna 102 are to be forwarded for further processing. The rear part 114 has, for example, a receptacle 126 on its rear side for accommodating electronic components for operating the waveguide antenna 102. For example, a circuit board 130 is arranged in the rear receptacle 126, from which the high-frequency signals are generated and fed to the waveguide antenna 102 via the antenna feed elements 118 for transmission. Furthermore, the circuit board 130 processes high-frequency signals received, for example, from the waveguide antenna 102 and forwarded via the antenna feed elements 118.Electrically conductive contact with the circuit board 130 is achieved, for example, by electronic lines 132, which extend, for example, through the connecting element 124 of the sensor housing 120 for connecting the waveguide antenna sensor component 100. The front and rear parts 112, 114 of the waveguide antenna 102 are connected to one another along a connecting line 116. The two interconnected parts 112, 114 enclose an interior of the waveguide antenna 102 with a waveguide structure. The sensor housing, manufactured by injection molding, encompasses an edge section 108 of the waveguide antenna 102, thereby holding it in position. A front panel 122 provided by the sensor housing 120 frames the metallized front section 106 encompassed by the front side 104.

[0056] Fig. 6 shows a detailed cross-section of a connection area between an exemplary waveguide antenna 102 and a sensor housing 120 manufactured by injection molding. The metallized plastic waveguide antenna 102 consists of two metallized plastic parts 112, 114, which are integrally connected along a connecting line 116. For example, the two parts 112, 114 are glued or soldered together. The front part 112 of the waveguide antenna 102 comprises a front side 104 with a metallized front section 106.

[0057] The injection-molded material of the sensor housing 120 surrounds an edge section 108 of the waveguide antenna 102 and forms a front panel 122, which frames the metallized front section 106 of the front part 112 of the waveguide antenna 102. The sensor housing is cast at a distance 103 from the metallized front section 106 in order to prevent the injection-molded material from overflowing onto the metallized front section 106. For example, the edge section 108 of the waveguide antenna 102 is not metallized in order to ensure adhesion between the edge section 108 and the Contacting the molded sensor housing 120. For example, the distance 103 is a distance between the molded sensor housing 120 and metallized areas of the waveguide antenna 102. For example, the distance 103 is part of a step 109, which in the case of Fig. 6 is configured as a bevel. A corresponding step 109 can, for example, more effectively prevent the injection-molded material from overflowing onto the metallized front section 106.

[0058] 7A to 7D show different exemplary embodiments of a step 109 between a metallized front section 106 of a metallized plastic waveguide antenna 102 and an edge section 108 of the waveguide antenna 102 encompassed by a sensor housing 120. For example, the step 109 extends all the way around the metallized front section 106. The step 109 effectively prevents injection molding material from overflowing onto the metallized front section 106 during the injection molding of the sensor housing 120. The exemplary step 109 shown in Fig. 7A is a vertical 90° step. The exemplary step 109 shown in Fig. 7B is a beveled or flattened step 109 with a flat angle of more than 90° and less than 180°. Fig. 7C shows an exemplary gradation 109 with a convex transition, while Fig. 7D shows an exemplary gradation 109 with a concave transition.

[0059] 8A to 8D show different exemplary embodiments of a dam structure 111 between a metallized front section 106 of a metallized plastic waveguide antenna 102 and an edge section 108 of the waveguide antenna 102 encompassed by a sensor housing 120. For example, the dam structure 111 extends all the way around the metallized front section 106. The dam structure 111 effectively prevents injection molding material from overflowing onto the metallized front section 106 during the injection molding of the sensor housing 120. The exemplary dam structure 111 shown in Fig. 8A includes side flanks raised perpendicular to the metallized front section 106. The exemplary dam structure 111 shown in Fig. 8B has beveled or flattened side flanks with a shallow angle of more than 90° and less than 180°. Fig.Fig. 8C shows an exemplary dam structure 111 with a convexly curved side flank, while Fig. 8D shows an exemplary step 109 with a concavely curved side flank.

[0060] Fig. 9A to 9D show different exemplary embodiments of a Edge section 108 of a metallized plastic waveguide antenna 102. The edge section 108 is encompassed by or cast into a sensor housing 120. For this purpose, the sensor housing is manufactured by injection molding. To achieve a secure connection between the cast edge portion 108 and the sensor housing 120, the edge portion 108 is not metallized, for example. This can be achieved, for example, by means of a selective coating process for applying the metal coating to the waveguide antenna 102. The edge portion 108 of the waveguide antenna 102 has, for example, an undercut 113. The sensor housing encompasses the undercut 113, which can ensure, for example, a secure positioning of the waveguide antenna 102 within the sensor housing.

[0061] The waveguide antenna 102 comprises, for example, a front part 112 and a rear part 114, which are connected to one another along a connecting line 116. For example, the waveguide antenna 102 has an undercut 113 on each of its front and rear sides. The undercut 113 on the front side of the waveguide antenna 102 extends, for example, around a metallized front section of the front part. Likewise, an undercut 113 on the rear side of the waveguide antenna 102 extends, for example, along an outer edge of the rear side. The exemplary undercut 113 shown in Fig. 9A is a vertical 90° undercut. The exemplary undercut 113 shown in Fig. 9B is beveled and has, for example, a wedge shape. Fig. 9C shows an exemplary undercut 113 with a convex shape, while Fig. 9D shows an exemplary undercut 113 with a concave shape.

[0062] Fig. 10 shows a front view of a waveguide antenna sensor component 100, which comprises a waveguide antenna 102 and a sensor housing 120. The waveguide antenna sensor component 100 shown in Fig. 10 corresponds to the waveguide antenna sensor component 100 shown in Fig. 4. Fig. 10 also shows a plurality of openings 107 for radar radiation, which are arranged in the metallized front section 106 of the waveguide antenna 102. Before the sensor housing 120 is manufactured, a dielectric film 140 covering the openings 107 is arranged, for example, on the metallized front section 106 of the waveguide antenna 102. The dielectric film 140 extends beyond the metallized front section 106, for example into the edge section 108 of the waveguide antenna 102, which is encompassed by the sensor housing 120 during production by injection molding.As a result, the sensor housing 120 extends over the edge of the dielectric film 140 and contributes to fixing the dielectric film 140 to the metallized front section 106 of the waveguide antenna 102.

[0063] Fig. 11 shows a side sectional view of the exemplary waveguide antenna sensor component 100 from Fig. 10. Visible in particular is the dielectric film 140, which is arranged on the metallized front section 106 of the waveguide antenna 102. The dielectric film 140 extends beyond the metallized front section 106 of the waveguide antenna 102. As a result, the sensor housing 120, manufactured by injection molding, extends over the edge of the dielectric film 140 and contributes to fixing the dielectric film 140 to the metallized front section 106 of the waveguide antenna 102.

[0064] Although the invention has been fully illustrated and described in the drawings and the foregoing description, this illustration and description is to be considered as illustrative and not restrictive; the invention is not limited to the disclosed embodiments. LIST OF REFERENCE SYMBOLS 100 waveguide antenna sensor component 102 waveguide antenna 103 distance 104 Front 106 Front Section 107 Opening 108 marginal section 109 Gradation 111 Dam structure 112 front part 113 Undercut 114 rear part 116 connecting line 118 Antenna feed element 120 sensor housings 122 front panel 124 connecting element 126 recording 130 circuit board 132 lines 140 dielectric foil

Claims

CLAIMS 1. A method for manufacturing a waveguide antenna sensor component (100) for a radar sensor, the method comprising: • Providing a waveguide antenna (102) in the form of a metallized plastic waveguide antenna (102), • Producing a sensor housing (120) enclosing the waveguide antenna (102) from plastic by means of injection molding, wherein the sensor housing (120) encompasses an edge section (108) of the waveguide antenna (102) and has a front panel (122) which frames a metallized front section (106) of the waveguide antenna (102).

2. The method of claim 1, wherein the method further comprises manufacturing the waveguide antenna (102), which comprises: • Providing a first part (112) of the waveguide antenna (102), which is a front part (112) of the waveguide antenna (102) made of plastic and comprising the front section (106), • Providing a second part (114) of the waveguide antenna (102), which is a rear part (114) of the waveguide antenna (102) made of plastic, • At least partially metallizing the first and second parts (112; 114) of the waveguide antenna (102), • Connecting the first and second metallized parts (112; 114) of the waveguide antenna (102) along a connecting line (116), wherein the two parts (112; 114) enclose an interior of the waveguide antenna (102) with a waveguide structure.

3. The method according to claim 2, wherein the first and second parts (112; 114) of the waveguide antenna (102) are connected to one another by means of a material connection.

4. Method according to one of claims 2 to 3, wherein the first and second parts (112; 114) of the waveguide antenna (102) are connected to one another by means of the sensor housing (120), which surrounds the edge section (108) of the waveguide antenna (102) in which the connecting line (116) extends.

5. The method of any one of the preceding claims, wherein the sensor housing (120) is in physical contact with the edge portion (108) of the waveguide antenna (102).

6. The method according to claim 5, wherein the metallization of the first and second parts (112; 114) of the waveguide antenna (102) is carried out using a selective coating process which leaves contact areas of the two parts (112; 114) forming the edge portions (108) of the waveguide antenna (102) free from the metallic coating.

7. Method according to one of the preceding claims, wherein the first part (112) and / or the second part (114) of the waveguide antenna (102) comprises at least one of the following geometric structures in a transition region adjacent to the edge section (108) of the waveguide antenna (102): a step (109) towards the edge section (108), a dam structure (111).

8. Method according to one of the preceding claims, wherein the edge portion (108) of the waveguide antenna (102) has one or more undercuts (113) which encompass the sensor housing (120).

9. Method according to one of the preceding claims, wherein the metallized front section (106) of the waveguide antenna (102) comprises a plurality of openings (107) for radar radiation, wherein, before the production of the sensor housing (120), a dielectric film (140) covering the openings (107) is arranged on the metallized front section (106) of the waveguide antenna (102) and extends beyond the metallized front section (106), wherein the sensor housing (120) extends at least over one edge of the dielectric film (140) and contributes to fixing the dielectric film (140) on the metallized front section (106) of the waveguide antenna (102).

10. The method according to any one of the preceding claims, wherein the sensor housing (120) further comprises one or more connecting elements (124) for mechanically connecting the waveguide antenna sensor component (100) to a receptacle of the vehicle provided for the waveguide antenna sensor component (100).

11. Waveguide antenna sensor component (100) for a radar sensor, wherein the waveguide antenna sensor component (100) comprises a waveguide antenna (102) in the form of a metallized Plastic waveguide antenna (102) which is enclosed by a sensor housing (120) made of plastic by injection molding, wherein the sensor housing (120) surrounds an edge section (108) of the waveguide antenna (102) and has a front panel (122) which frames a metallized front section (106) of the waveguide antenna (102).

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