Low entry force connector socket method of manufacture

A method of making a connector socket for engaging a connector pin, said socket being of the kind comprising a generally cylindrical inner cage having an upper end rim and a lower end rim, a plurality of contact wires positioned within said cage, said contact wires being rotationally offset from one end of said cage to the other and hooked in notches in the upper end rim and the lower end rim of said cage to thereby define a pin-engaging wire basket having a virtual minimum diameter smaller than the outer diameter of said pin, and enclosing means for enclosingly engaging said cage and the hooked ends of said wires, said method comprising:

• inserting a tool pin into said wire basket after its construction within said cage but before application of said enclosing means, said tool pin having a diameter selected in view of the diameter of said connector pin with which the socket is to be used and the desired connecting force;
• thereafter, while said tool pin is inserted in said wire basket, applying said enclosing means around said cage to grippingly engage said cage and said hooked ends of said wire, to thereby fix the connecting force of said socket;
• and
• thereafter removing said tool pin from said wire basket.

A method of making a connector socket for engaging a connector pin, said socket being of the kind comprising a generally cylindrical inner cage having an upper end rim and a lower end rim and a pair of circumferential ribs thereon at a mid region thereof, a plurality of contact wires positioned within said cage, said contact wires being rotationally offset from one end of said cage to the other and hooked in notches in the upper end rim and the lower end rim of said cage to thereby define a pin-engaging wire basket having a virtual minimum diameter smaller than the outer diameter of said pin, and enclosing means for enclosingly engaging said cage and the hooked ends of said wires, said method comprising:

• inserting a tool pin into said wire basket after its construction within said cage but before application of said enclosing means, said tool pin having a diameter selected in view of the diameter of said connector pin with which the socket is to be used and the desired connecting force;
• thereafter, while said tool pin is inserted in said wire basket, applying said enclosing means around said cage to grippingly engage said cage and said hooked ends of said wires, to thereby fix the connecting force of said socket;
• thereafter removing said tool pin from said wire basket;
• and
• deforming the edges of said cap and body therearound to unify the parts of said connector socket electrically and mechanically.

A method of making a connector socket for engaging a connector pin, said socket being of the kind comprising a generally cylindrical inner cage, a plurality of contact wires positioned within said cage, said contact wires being rotationally offset from one end of said cage to the other by a selected angle and hooked in notches in the end rims of said cage to thereby define a pin-engaging wire basket having a virtual minimum diameter smaller than the outer diameter of said pin, and enclosing means for enclosingly engaging said cage and the hooked ends of said wires, said method comprising:

• providing wire seating notches on the rims of each end of said cage, each of said wires having three seating notches associated therewith, a first notch on a first cage end rim, a second notch on a second cage end rim and rotationally offset from said first notch by an angle smaller than said selected angle, and a third notch on said second cage end rim and rotationally offset from said first notch by said selected angle;
• feeding each of said wires into said cage in a path of movement substantially parallel to the axis of said cage;
• hooking a first end of each of said wires on its said first notch;
• hooking a second end of each of said wires on its said second notch;
• moving the hooked second end of each of said wires from its said second notch to its said third notch thereby forming said wire basket;
• inserting a tool pin into said wire basket after its construction within said cage but before application of said enclosing means, said tool pin having a diameter selected in view of the diameter of said connector pin with which the socket is to be used and the desired connecting force;
• thereafter, while said tool pin is inserted in said wire basket, applying said enclosing means around said cage to grippingly engage said cage and said hooked ends of said wires, to thereby fix the connecting force of said socket;
• thereafter removing said tool pin from said wire basket;
• and
• enclosing said cage in said enclosing means.