Method of manufacture of low-cost, high quality low insertion force electrical connector socket

Claim 1

The method of manufacture of a low insertion force electrical connector socket, comprising: forming a length of generally tubular stock to have a generally conical inside and outside taper over a first predetermined distance (E & F) from a first end thereof; thereafter axially slotting the side walls of said tubing from said first end to a second predetermined distance (D), said second distance not exceeding said first distance, said slotting forming a pair of tines of length equal to said second distance from said first end to a tine root region; and partially flattening said tines while preventing plastic deformation of said tines at said root region, said partial flattening being such as to substantially modify the inside radius of said tines at least to that of said tubular stock prior to said forming operation over a third predetermined axial distance (F) from said first end, said third predetermined distance (F) being less than said second predetermined distance (D).

Claim 2

The method of manufacture of a low insertion force electrical connector socket, comprising: forming a length of generally tubular stock to have a generally conical inside and outside taper over a first predetermined distance (E & F) from a first end thereof; thereafter axially slotting the side walls of said tubing from said first end to a second predetermined distance (D), said second distance not exceeding said first distance, said slotting forming a pair of tines of length equal to said second distance from said first end to a tine root region; and partially flattening said tines while preventing plastic deformation of said tines at said root region, said partial flattening being such as to substantially modify the inside radius of said tines at least to that of said tubular stock prior to said forming operation over a third predetermined axial distance (F) from said first end, said third predetermined distance (F) being less than said second predetermined distance (D).

Claim 6

The method of manufacturing an electrical connector socket having an aperture end for receiving a conductive pin of substantially uniform circular cross-section in response to a relatively low axial insertion force, comprising: forming a generally tubular socket body of resilient metal with a first body portion of first predetermined axial length (C) and of predetermined cross-sectional characteristics for a fixed connection interface; forming a second portion of said socket body for a second predetermined axial length (E & F) extending from said first body portion toward said aperture end as a right, circular, conical shell having a conical inside and outside taper, and converging to a diameter reduced at said aperture end as compared to the largest cross-sectional diameter of said conical shell, body portion; thereafter cutting at least two axially extending, equally circumferentially spaced slots through the wall thickness of said second body portion to produce bifurcation of said second body portion from said aperture end, the plural tines thereby provided being of third predetermined length (D) not greater than said second predetermined length, the nonaperture ends of said slots terminating to produce a tine root region, the modulus of elasticity of said root region being thereby not subjected to nonuniform work hardening.

Claim 7

The method of manufacturing an electrical connector socket having an aperture end for receiving a conductive pin of substantially uniform circular cross-section in response to a relatively low axial insertion force, comprising: forming a generally tubular socket body of resilient metal with a first body portion of first predetermined axial length (C) and of predetermined cross-sectional characteristics for a fixed connection interface; forming a second portion of said socket body for a second predetermined axial length (E & F) extending from said first body portion toward said aperture end as a right, circular, conical shell having a conical inside and outside taper, and converging to a diameter reduced at said aperture end as compared to the largest cross-sectional diameter of said conical shell, body portion; thereafter cutting at least two axially extending, equally circumferentially spaced slots through the wall thickness of said second body portion to produce bifurcation of said second body portion from said aperture end, the plural tines thereby provided being of third predetermined length (D) not greater than said second predetermined length, the nonaperture ends of said slots terminating to produce a tine root region, the modulus of elasticity of said root region being thereby not subjected to nonuniform work hardening.

Claim 8

The method of manufacture of a low insertion force electrical connector socket, comprising: forming a length of generally tubular stock to have a generally conical inside and outside taper over a first predetermined distance (E & F) from a first end thereof; and thereafter axially slotting the side walls of said tubing from said first end to a second predetermined distance (D), said second distance not exceeding said first distance, said slotting forming a pair of tines of length equal to said second distance from said first end to a tine root region whereby plastic deformation of said tines at said root region is avoided.

Claim 9

The method of manufacture of a low insertion force electrical connector socket, comprising: forming a length of generally tubular stock to have a generally conical inside and outside taper over a first predetermined distance (E & F) from a first end thereof; and thereafter axially slotting the side walls of said tubing from said first end to a second predetermined distance (D), said second distance not exceeding said first distance, said slotting forming a pair of tines of length equal to said second distance from said first end to a tine root region whereby plastic deformation of said tines at said root region is avoided.