As electronic devices continue to shrink in size, the demand for efficient use of space within their enclosures becomes ever more critical. In the realm of handheld devices like cell phones, PDAs, laptops and MP3 players, the need for compact yet effective placement of crucial components such as antennas has never been greater. Gone are the days when a 0.01” proximity between components was deemed acceptable; today’s standards demand tolerances as tight as 0.005” or smaller. This shift presents significant challenges for engineers tasked with finding manufacturing solutions.
The performance of components like antennas can be significantly enhanced when their proximity to other live components is tightly controlled within the range of 0.005” to 0.010”. Achieving such precision, however, often comes with a hefty price tag and logistical complexities. Overcoming these obstacles requires not only proper tooling and equipment but also a commitment to ensuring product success and reliability in the marketplace while maintaining profitability.
In the images above, we illustrate the transformative impact of precise antenna placement in handheld devices. Take, for example, the case of a cell phone antenna that needs to conform to the curved shape of its housing. By bending the antenna 0.050” away from the PCB directly above it, the distance between the two components nearly doubles, greatly enhancing antenna performance.
There are two primary methods to achieve this crucial increase in distance. One option is to source pre-bent antennas from suppliers, but this approach often comes with a hefty price tag and requires specialized packaging to prevent damage during transit. Alternatively, investing in high-quality tooling and equipment to perform the bending during the assembly process can yield significant cost savings and increased component yield.
At Thermal Press International (TPI), we take pride in designing machines that offer the accuracy and repeatability necessary to meet the stringent requirements of heat staking in precision manufacturing. Our equipment enables manufacturers to achieve precise heat staking requirements, resulting in tangible savings and improved product performance.
In both examples highlighted, manufacturers were able to procure antennas at competitive prices with short lead times. In both scenarios, the antennas arrived flat, with the bending process seamlessly integrated into the assembly process using specialized tooling and heat staking equipment.
By collaborating with TPI engineers during the development stage, manufacturers can accurately calculate the degree of bending required and incorporate it into the heat stake tool as a standard feature. This proactive approach to product design ensures that precise antenna placement is seamlessly integrated into the manufacturing process, setting a new standard of excellence in this category.
