Vehicular sensor module with overmolded housing structure

A vehicular sensor, the vehicular sensor comprising:

• a vehicular sensor housing comprising a first housing portion and a second housing portion, wherein the first housing portion and the second housing portion are joined together;
• a sensor accommodated by the vehicular sensor housing;
• wherein the first housing portion comprises a plastic portion overmolded partially over a metallic heat dissipating element;
• wherein the metallic heat dissipating element comprises a first side and a second side opposite the first side, and wherein an engagement structure is formed at the first side of the metallic heat dissipating element;
• wherein the plastic portion, when overmolded partially over the metallic heat dissipating element, at least partially fills recesses between portions of the engagement structure formed at the first side of the metallic heat dissipating element;
• wherein, with the plastic portion overmolded partially over the metallic heat dissipating element, an overmolded portion of the first side of the metallic heat dissipating element is overmolded by the plastic portion and an exposed portion of the first side of the metallic heat dissipating element is not overmolded by the plastic portion;
• and
• wherein, with the first housing portion joined to the second housing portion of the vehicular sensor housing, (i) the exposed portion of the first side of the metallic heat dissipating element is exposed within the vehicular sensor housing and (ii) the second side of the metallic heat dissipating element that is opposite the first side is at least partially exposed exterior of the vehicular sensor housing.

A method for manufacturing a vehicular sensor housing, the method comprising:

• providing a metallic heat dissipating element;
• laser etching the metallic heat dissipating element to form an engagement structure at a first side of the metallic heat dissipating element, and wherein the engagement structure is at a perimeter region of the first side of the metallic heat dissipating element;
• with the laser etched metallic heat dissipating element disposed in a mold, injecting an uncured plastic material into the mold to form a heat dissipating housing portion of the vehicular sensor housing, wherein the uncured plastic material flows at least partially along the first side of the metallic heat dissipating element and at least partially fills recesses between portions of the engagement structure at the first side of the metallic heat dissipating element;
• wherein, with the plastic material cured, the heat dissipating housing portion is joined to another portion of the vehicular sensor housing, and wherein, with the heat dissipating housing portion joined to the other portion of the vehicular sensor housing, (i) a portion of the first side of the metallic heat dissipating element is exposed within the vehicular sensor housing and (ii) at least a portion of a second side of the metallic heat dissipating element that is opposite the first side is exposed exterior of the vehicular sensor housing;
• and
• wherein the portion of the first side of the metallic heat dissipating element exposed within the vehicular sensor housing is configured to thermally interface with a heat-generating component disposed within the vehicular sensor housing.