Molding designs for helical antennas

A method comprising:

• placing an antenna element between a top mold core and a first bottom mold core;
• injecting molding material into a first mold cavity defined by at least the top mold core, thereby forming a top portion of a helical antenna housing and two opposite side portions of the helical antenna housing;
• removing the first bottom mold core and placing a second bottom mold core about the antenna element;
• and
• injecting molding material into a second mold cavity defined by at least the second bottom mold core, thereby forming a bottom portion of the helical antenna housing;
• wherein:
• the helical antenna housing includes at least one helical portion of the molding material that protrudes outwardly from an exterior surface of the helical antenna housing;
• the top mold core includes a first sliding element and a second sliding element, the method further comprising moving the first sliding element away from the helical antenna housing and moving the second sliding element away from the helical antenna housing to release the helical antenna housing from the top mold core;
• and
• the at least one helical portion of the molding material creates at least one undercut feature that inhibits removal of the helical antenna housing from the top mold core such that the helical antenna housing is adapted to remain in the top mold core until the first sliding element and the second sliding element are moved away from the helical antenna housing and release the at least one undercut feature, thereby allowing the helical antenna housing to be removed from the top mold core.

A method comprising:

• placing an antenna element between a top mold core and a first bottom mold core;
• injecting molding material into a first mold cavity defined by at least the top mold core, thereby forming a top portion of a helical antenna housing and two opposite side portions of the helical antenna housing;
• removing the first bottom mold core and placing a second bottom mold core about the antenna element;
• and
• injecting molding material into a second mold cavity defined by at least the second bottom mold core, thereby forming a bottom portion of the helical antenna housing;
• wherein:
• the helical antenna housing includes at least one helical portion of the molding material that protrudes outwardly from an exterior surface of the helical antenna housing;
• the at least one helical portion of the molding material creates at least one undercut feature that inhibits removal of the helical antenna housing from the top mold core;
• the top mold core includes at least one sliding element;
• and
• the method further comprises moving the at least one sliding element away from the helical antenna housing to release the at least one undercut feature, thereby allowing the helical antenna housing to be removed from the top mold core.