Vehicular radar sensor with mechanical coupling of sensor housing

A radar sensor for a vehicular radar sensing system, wherein the radar sensor is configured to be disposed at a vehicle so as to sense exterior of the vehicle, the radar sensor comprising:

• a housing structure and at least one printed circuit board (PCB);
• wherein the housing structure comprises a front housing, a rear housing and an intermediate frame disposed between the front housing and the rear housing;
• wherein the PCB is accommodated between the front housing and the rear housing in a cavity established within the housing structure when the front housing and the rear housing are joined together via the intermediate frame;
• wherein the rear housing is secured to the intermediate frame via a plurality of fasteners;
• and
• wherein the front housing is secured to the intermediate frame via welding.

A radar sensor for a vehicular radar sensing system, wherein the radar sensor is configured to be disposed at a vehicle so as to sense exterior of the vehicle, the radar sensor comprising:

• a housing structure and at least one printed circuit board (PCB);
• wherein the housing structure comprises a front housing and a rear housing;
• wherein the PCB is accommodated between the front housing and the rear housing in a cavity established within the housing structure when the front housing and the rear housing are joined together;
• wherein the rear housing includes at least one alignment pin protruding therefrom, and wherein the at least one alignment pin is received in at least one alignment aperture at the PCB to align the PCB with the rear housing during assembly of the radar sensor;
• wherein, with the at least one alignment pin received in the at least one alignment aperture, the PCB is engaged with the rear housing via a plurality of protrusions at the rear housing;
• wherein a gasket element is disposed between the front housing and the rear housing to seal a junction of the front housing and the rear housing when the front housing and the rear housing joined together;
• wherein the rear housing is joined to the front housing via a clip that at least partially circumscribes the junction between the front housing and the rear housing;
• wherein the clip comprises (i) a center strip that at least partially circumscribes the junction, (ii) a plurality of rear flanges protruding from the center strip that engage the rear housing and (iii) a plurality of front flanges protruding from the center strip that engage the front housing;
• and
• wherein, with the center strip at least partially circumscribing the junction, the rear flanges are adapted to engage the rear housing and the front flanges are adapted to engage the front housing so as to secure the rear housing and the front housing together.