Method of manufacturing an antenna
A method of manufacturing a stamped antenna includes providing a sheet of metallic material for a first stamping. A first stamping of the sheet of metallic material is performed to form at least one antenna that includes traces, contacts, a carrier connected to the traces, and at least one tie-bar connected between the traces. A pad is provided with at least one pressure sensitive adhesive area that is provided on the pad in substantially the same shape as the traces of the antenna. The pressure sensitive adhesive area is aligned with the traces of the antenna, and then bonded to the traces of the at least one antenna. A second stamping of the at least one antenna and the pressure sensitive adhesive is then performed to remove the at least one carrier and the at least one tie-bar connected to the traces.
1. A method of manufacturing an antenna, comprising:
providing a sheet of metallic material;
performing a first stamping of the sheet of metallic material to form at least one antenna, the at least one antenna including traces, contacts, a carrier connected to the traces, and at least one tie-bar connected between the traces;
providing a pad with at least one pressure sensitive adhesive area, the at least one pressure sensitive adhesive area provided on the pad in substantially the same shape as the traces of the at least one antenna;
aligning the at least one pressure sensitive adhesive area with the traces of the at least one antenna after the at least one antenna has been stamped for a first time;
bonding the at least one pressure sensitive adhesive area to the traces of the at least one antenna after the at least one antenna has been stamped for a first time and the at least one pressure sensitive adhesive area has been aligned with the traces of the at least one antenna; and
performing a second stamping of the at least one antenna and the at least one pressure sensitive adhesive area to remove the at least one carrier and the at least one tie-bar connected to the traces.
2. The method of manufacturing an antenna of claim 1 , wherein the first stamping forms more than one antenna as a group connected by at least one tie-bar or the carrier.
3. The method of manufacturing an antenna of claim 2 , wherein the pad includes more than one pressure sensitive adhesive area.
4. The method of manufacturing an antenna of claim 3 , wherein the more than one antenna are separated from one another after the second stamping.
5. The method of manufacturing an antenna of claim 1 , wherein the carrier includes at least one pilot hole and the pad includes at least one die cut hole.
6. The method of manufacturing an antenna of claim 5 , further comprising:
placing the antenna stamped for a first time on a fixture having at least one fixture pin, the fixture pin being inserted through the at least one pilot hole;
placing the pad on the fixture, the fixture pin being inserted through the at least one die cut hole;
wherein the fixture pin aligns the first stamped antenna and the pad such that the at least one pressure sensitive adhesive area of the pad is positioned on the traces of the antenna.
7. The method of manufacturing an antenna of claim 6 , wherein the fixture is a pallet.
8. The method of manufacturing an antenna of claim 1 , wherein the sheet of metallic material is copper.
9. The method of manufacturing an antenna of claim 1 , further comprising:
bonding a ferrite shield to the at least one antenna stamped for a second time.
10. The method of manufacturing an antenna of claim 9 , wherein the carrier includes a pilot hole, the pad includes a first and a second die cut hole, and the ferrite shield includes a pilot hole.