Patent Publication Number: US-6656002-B2

Title: Electrical terminal socket assembly including T shaped sealed connectors

Description:
REFERENCE TO COPENDING APPLICATIONS 
     The present application is a continuation-in-part application of U.S. application Ser. No. 09/951,012, filed Sep. 14, 2001, entitled “Electrical Terminal Socket Assembly Including Both T-Shaped and 90° Angled and Sealed Connectors”; and claims benefit of U.S. Provisional Application No. 60/271,776, filed Feb. 27, 2001, entitled “Power Feed Attachment”; and U.S. Provisional Application No. 60/232,698, filed Sep. 15, 2000, entitled “Power Feed Attachment”. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to sealed power connectors and feed attachments, such including resilient engagement capability. More particularly, the present invention is directed to an electrical terminal socket which incorporates a hectically wound and compressible spring cage and an encircling tubular shaped and compressible terminal sleeve for holding the spring cage in place. The present assembly provides a low cost solution for a quick connect assembly and which requires a much greater degree of torque control in assembly as opposed to prior art bolt and nut type cable connections. The present invention further discloses variations of “T” shaped sealed connection assemblies, and which include the terminal socket assembly enclosed within interengaging male and female outer connecting portions, for better insulating and sealing the electrical connections established by the socket assembly. 
     BACKGROUND OF THE INVENTION 
     Electrical connectors of the terminal socket variety are well known in the art, one primary application of which being in the automotive field for establishing connections between heavier sized output cable and components such as generators or alternators. The frictional grip imparted by the connector must be of sufficient strength to maintain firm mechanical and adequate electrical connection, yet must permit relatively easy manual withdrawal or insertion of a prong into the connector socket. 
     One type of known prior art electrical cable connection is the bolt-nut type electrical cable connection. A significant problem associated with such bolt and nut arrangements arises from the amount of torque which is necessary to assemble the connector and the difficult quality control issues which arise from its large scale use such as over torque, under torque and cross thread. 
     Generally, it has also been difficult to manufacture spring cage socket terminals, designed from either a single piece of material or assembled from parts, which may include a plurality of individual connector strips or wires. In instances where the terminal is constructed in one piece, several complex machining and forming steps are required. Additionally, construction of a socket terminal starting with individual contact strips requires a tedious assembly process and involving more than four (4) components. As such, manual assembly involving socket terminals is both an intricate and difficult task, as well as a necessary one, and significantly increases a cost of production associated with the connector. 
     Another example of a radially resilient terminal socket is set forth in U.S. Pat. No. 4,657,335, issued to Koch, and which teaches constructing a barrel terminal socket by forming a sheet metal blank with uniformly spaced, parallel, longitudinal strips integrally connected at their opposite ends to transversely extending webs. The blank is then formed into a cylinder, inserted into a close-fitting cylindrical sleeve and one end of the blank is fixedly secured to the sleeve. The opposite end of the blank is then rotated relative to the sleeve through a predetermined angle and then fixedly secured in its rotated position to the sleeve. Accordingly, Koch teaches a multiple of individual assembly steps and the use of no less than five (5) separate components, which are necessary to complete the construction of the terminal socket. 
     U.S. Pat. No. 4,734,063, also issued to Koch, discloses additional, methods and techniques for constructing the barrel terminal, including the contactor strip portions being provided as a plurality of individual and spaced apart blanks attached to a carrier strip (46). Each blank is advanced through a number of work stations and assembled utilizing no less than four (4) components, such varied assembly steps including forming the contactor strips into a hollow barrel configuration and fitting the sleeve onto the barrel configured blank. 
     In summary, the above two prior art patents each utilize at least four (4) or more components in order to construct a power terminal, the net effect of which is to increase the cost, render more complex the design, and slow processing of the parts. It is further found that the provision of many joints, connecting these components together, decreases the effective contact surface for effecting the electrical communication, and has been found to be less reliable and have more potential failure modes. 
     In sum, it has been determined that it is important to maintain sufficient contact surface and in order to guarantee that an adequate amount of electrical current is carried through the terminal assembly. 
     SUMMARY OF THE INVENTION 
     The present invention discloses an electrical terminal socket assembly which incorporates a helically wound and compressible spring cage and an encircling tubular shaped and compressible “T” shaped terminal sleeve for holding the spring cage in place. As previously explained, the present assembly provides a low cost solution for a quick connect assembly and which requires a much greater degree of torque control in assembly, as opposed to prior art bolt and nut type cable connections. The present invention is also an improvement over prior art assembly techniques which require the spring cage element to be formed in place after it has been inserted into the corresponding sleeve component, particularly in that the present invention provides only two components and a simplified assembly process. It is further contemplated that the assembly part can be manufactured in conjunction with a fast speed progression die. 
     A spring cage blank has first and second extending edges and a plurality of spaced apart and angled beams extending between the edges. In a preferred variant, a plurality of the spring cage blanks are provided in spaced fashion between first and second carrier strips and which permit the blanks to be transferred in succession into an appropriate die stamping or forming operation. Such stamping or other suitable forming operation typically includes the provision of first and second spaced apart and opposing mandrels, each further including a substantially cylindrical projection with inwardly sloping walls engaging thereupon the associated extending edges of the spring cage. 
     In one variant, female die patterns are employed in one or more stamping/forming operation to form the spring cage blank in to a substantially cylindrical configuration and in which the angled beams are arranged in a substantially helix pattern. In a still further variant, the stamping dies are succeeded by alternately configured forming dies, the purpose of which being to grasp the opposite extending edges of a substantially formed spring cage and subsequently to torsionally bend the spring cage a specified angular degree in a direction consistent with the angle established by the beams. Depending upon the configuration of the female die surfaces, and/or the application of the torsional bending step, the formed spring cage may further exhibit a substantially “hourglass” shape and which will improve its connector biasing qualities in subsequent use. 
     A substantially tubular shaped and interiorly hollowed sleeve is provided for receiving the substantially cylindrically/hourglass shaped spring cage in axially inserting and fixedly and pressure retaining fashion. The spring cage is typically dimensioned to slidably engage within the axial interior of the tubular sleeve without an excessive amount of effort. The sleeve is in turn typically slitted or otherwise configured so that opposing edges are separated by a specified gap and are capable of being compressingly engaged together. In one preferred variant, meshing keyed portions are defined along the slitted and gapped surface and so that, upon inserting assembly of the formed spring cage, the exterior surface of the sleeve is compressingly engaged (such as again through the employed of stamping dies or other suitable manufacturing operation) and in order to create a desired interference fit between the spring cage and the interior of the sleeve. 
     The interference fit created between the spring cage and sleeve provides the primary retaining feature of the terminal socket assembly. Additionally however, a lance is associated with a transition area of the tubular sleeve and functions as a cage forward stop. A front dish-like feature is installed after the cage is located in proper position. The front dish-like feature functions as a forward stop and further assists in retaining the cage inside the sleeve. It is again understood that the lance and dish-like feature are supplemental features which assist in retaining the cage inside the tubular sleeve. 
     In order to complete the electrical connection, an extending end of a male pin is secured within the interiorly hollowed sleeve and assembled spring cage. The sleeve, in any of a number of alternate variants, further includes actuable gripping portions for fixedly engaging against and securing an extending end of a cable. The gripping portions may further be configured so that the cable extends in an angular (typically 90°) relationship relative to the male pin secured to the sleeve and spring cage assembly. 
     As is particularly disclosed in the present application, assembly configurations of the quick connect socket assembly disclose variations of “T” shaped sealed assemblies. Also, sealed housing assemblies disclosed by the present invention include interengaging male and female outer connecting portions and associated seals and retainers, for electrically and environmentally sealing and insulating the socket assembly and extending cables. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an illustration of spring cages, in initial flat blank form, exhibiting a plurality of angled and spaced apart beams, and which are supported between upper and lower carrying strips according to the preferred embodiment of the present invention; 
     FIG. 2A is an illustration of the spring cage blank after a first forming operation, and in which the angled and spaced apart beams extend according to a given arcuate and pre-calculated curvature; 
     FIG. 2B is a cutaway view taken along line  2 — 2  of FIG.  2 A and which illustrates a side view configuration of the selected spring beam illustrated in FIG. 2A, prior to subsequent forming operations performed according to the present invention; 
     FIG. 3A illustrates an operating station employed in a spring cage bending operation according to a preferred variant and in which an initial forming operation is performed upon the previously arcuately formed beams of the spring cage blank of FIG.  2 A and by compression forming a selected spring cage blank about a pair of opposing and configured mandrels secured, respectively, to first and second actuating cylinders; 
     FIG. 3B illustrates a further operating station employing a further compression forming operation to a semi-cylindrically configured spring cage; 
     FIG. 3C illustrates a yet further operating station in which a yet further compression forming operation is performed to a more substantially and cylindrically configured spring cage; 
     FIG. 3D illustrates a final operating station in which a her compression forming operation is performed to complete the cylindrical spring cage shaping of the blank and in which opposite joining ends of first and second extending ends are over-flexed in opposite directions in order to establish an on-plane configuration during subsequent material spring-back; 
     FIG. 4 illustrates a spring cage bending operation according to a second preferred variant of the present invention and in which a single forming stage again includes a pair of opposing and cylinder actuated mandrels, combined with first and second opposing and actuable forming dies defining collectively a substantially hourglass-shape configuration to be imparted to the spring cage; 
     FIG. 4A is a cutaway view taken along line  4 A— 4 A in FIG.  4  and illustrating, in side cutaway profile, the arcuate hourglass configuration established between mating female die surfaces and which also completes the progression set forth in FIGS. 2A to  4 A to illustrate the manner in which the contact beams of the cage are formed and constructed in a substantially hourglass configuration; 
     FIG. 5 illustrates a spring cage bending operation according to a third preferred variant of the present invention, substantially as presented in the variant of FIG. 4, and in which, in a first forming operation, the mating female die surfaces are configured to provide a cylindrically formed spring cage with a larger and substantially constant radius; 
     FIG. 6 illustrates a succeeding forming operation, to any of the afore-described preferred variants, and which provides an operating station including first and second pairs of opposingly actuable forming dies each of which including meshing teeth which, in combination with the cylinder actuable mandrels, grasp the end connecting belts of the associated and cylindrically formed spring cage to impart a further twisting and torsional profile; 
     FIG. 7 illustrates a substantially formed spring-cage and which exhibits both a helical winding pattern to the spaced beams as well as a substantially hourglass configuration; 
     FIG. 8 is an exploded illustration of a substantially assembled and tubular/compressible terminal sleeve, housing a formed and inserted spring-cage for mating with a male pin, and within an opposite end of which is engaged an existing vehicle cable according to the present invention; 
     FIG. 8A is an illustration of the terminal sleeve provided in an initially blank-shape prior to subsequent forming operations performed according to the present invention; 
     FIG. 8B is an illustration, similar to that illustrating in FIG. 8, and in which the engaging end of male pin is illustrated mated to the sleeve terminal according to the present invention; 
     FIG. 9 is an exploded view of an assembly operation for inserting and fixing a formed spring cage within a terminal sleeve according to the present invention; 
     FIG. 10 is a cutaway view taken along line  10 — 10  of FIG. 9, following insertion of the spring cage into the sleeve, and illustrating the biasing nature of the compressible sleeve applied to the cage in order to create an interference fit therebetween; 
     FIG. 11 is a first exploded view of a sealed terminal arrangement according to the present invention and which incorporates an eyelet terminal and associated O-ring; 
     FIG. 12 is a second exploded view of an unsealed terminal arrangement similar to that illustrated in FIG. 11 and, as with both FIGS. 11 and 12, an outer diameter of the spring cage being substantially equal to or slightly smaller than a corresponding inside diameter of the tube which is compressible about the inserted spring cage; 
     FIG. 13 is an exploded view of an assembly operation according to a further preferred variant of the invention and in which an outer diameter of the spring cage is substantially equal to or slightly smaller than an inside diameter of a modified terminal sleeve, which is compressible about the inserted spring cage; 
     FIG. 14 is an exploded view of a 90 degree variant of a terminal sleeve according to the present invention; 
     FIG. 15 is an illustration of a button-type terminal sleeve for use in a “T” shape sealed connector according to the present invention; 
     FIG. 15A is a side cutaway view of a “T” shaped terminal assembly such as is generally shown in FIG.  15  and illustrating in side cutaway a first interengaging configuration of the extending bracket portions and buttons; 
     FIG. 15B is a side cutaway view of a “T” shaped terminal assembly such as again is generally shown in FIG.  15  and illustrating in side cutaway a further engaging configuration of the buttons extending from a first selected bracket portion and through apertures defined in an aligning portions of the other selected bracket portion; 
     FIG. 15C is a side cutaway view of a “T” shaped terminal assembly according to a a further preferred variant of the present invention and which illustrates, in side cutaway, a weld joint established between two brackets and welding of a trailing edge of a first bracket portion to an upper planar surface of the other and integrally extending bracket portion; 
     FIG. 15D is a side cutaway view of a “T” shaped terminal assembly according to a still further preferred variant of the present invention and which illustrates, once again in side cutaway, riveting of a first selected bracket portion to the other and integrally extending bracket portion; 
     FIG. 15E is a side cutaway view of a “T” shaped terminal assembly according to a yet further preferred variant and including an engaging configuration including a rivet which projects through apertures defined in aligning portions of both selected bracket portions; 
     FIG. 16 is an exploded view of a “T” shaped sealed connector incorporating the button-type terminal illustrated in FIG. 15; and 
     FIG. 17 is an exploded view of a 90° sealed connector according to a further assembled variant of the present invention. 
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     Referring to the appended drawing illustrations, and in particular to FIGS. 8 and 8B, a terminal socket assembly is illustrated at  10  according to one preferred variant and in order to interconnect electrically powered vehicular components (not shown) via an associated male pin  12  and a cable  14 , such connecting inputs as pins and cables typically corresponding to an input or output of selected vehicular components. As previously described, the terminal assembly and method for constructing provides a low cost solution for a quick connect assembly and which requires a much greater degree of torque control in assembly, as opposed to prior art bolt and nut type cable connections. The present invention is also an improvement over prior art assembly techniques which require the spring cage element to be formed in place after it is has been inserted into the corresponding sleeve component. 
     Referring again to FIG. 1, a spring cage blank assembly is generally illustrated at  16  and, in the preferred embodiment, includes individual and spaced apart spring blanks  18 ,  20 , et seq., which are supported upon a pair of first  22  and second  24  carrier strips. The carrier strips  22  and  24  each in turn include spaced apart and axially defined apertures  26  (defined through both top  22  and bottom  24  strips) as well as establishing connecting portions with the blanks (see connecting portions  28  and  30  for spring cage blank  18  and connecting portions  32  and  34  for blank  20 ). 
     The apertures  26  defined in the upper and lower carrier strips permit the assembly  16  to be transported upon a suitable conveying apparatus (not shown), such as which operates in conjunction with a suitable stamping or forming operation (as will be hereinafter described). The connecting portions  32 ,  34  and  36 ,  38  further function to provide first and second supporting locations for the subsequent shaping and forming operations to be performed on each of the spring cage blanks  18 ,  20 , et seq. 
     The spring cage blanks  18 ,  20 , et seq., are each constructed of a spring copper material, having a specified thickness and configuration. In particular, and referencing the blank  18 , the spring cage includes a first (or upper) extending edge  40  (secured to the first carrier strip  22  via upper connecting portions  28  and  32 ) and a second opposite and spaced apart (lower) extending edge  42  (secured to the second carrier strip  24  via lower connecting portion  30  and  34 ). 
     A plurality of spaced apart and angled beams  44  extend between the extending edges  40  and  42  and, in a preferred embodiment, are provided at an angle ranging typically from between 4° to 25° relative to a longitudinal direction (see at  46 ) and in order to provide the plan view appearance of the spring clip  18  with an overall parallelogram shape. It is however understood that the spaced apart beams  44  may be provided at any suitable angle relative to the upper  40  and lower  42  extending edges, the result of which typically having some affect on contact force between male pin and terminal socket assembly. 
     General illustration  16 ′ of the spring blank assembly in FIG. 2A illustrates, in particular, a selected spring cage blank  18 ′ having undergone a first processing or forming operation and in which an arcuate curvature is formed into each of the spaced apart and angle beams (see at  44 ′). The spring cage blanks  16 ′ and  20 ′ are otherwise substantially identical to that also illustrated at  16  in FIG.  1  and it is understood that any suitable type of bending, stamping or initial forming operation may be provided in order to create the necessary arcuate curvature in the spaced apart beams  44 ′. It is also envisioned that the spring cage to be formed can be created from a blank as originally shown in FIG. 1, without the additional operation performed by FIG. 2A, and within the scope of the invention. 
     Referring further to FIG. 2B, the selected spring clip blank  16 ′ in FIG. 2A is illustrated in side cutaway profile and exhibiting a cross sectional arcuate profile designed into the extending and angled beams  44 ′. In a preferred variant, a pre-calculated radius is designed into the cross sectional geometry of the beams  44 ′ so that, during subsequent forming operations, the spring clip acquires the desired substantially hourglass shape (see at  18 ′ in FIG. 7) for subsequent application within the socket assembly  10 . As is also illustrated by formed spring clip  18 ′, an “hourglass” shape may be created and reference is made to the following description. 
     Referring back to FIGS. 1 and 2A, it is also understood that the second spring cage blank  20  and  20 ′ (as well as each succeeding blank located along the carrier strips  22  and  24 ) is constructed in substantially identical fashion to that more completely illustrated and described at  18 . Accordingly, repetitive enumeration and description of the corresponding elements in second blank  20  is foregone and for purposes of ease of illustration. 
     Referring to FIGS. 3A-3D collectively, a forming operation is illustrated according to a first variant for shaping the spring cage blanks  18 ′,  20 ′, et seq., into the substantially cylindrical and, in specified instances, hourglass configuration of the spring cage (see again at  18 ′ in FIG.  7 ). Specifically, the forming operation according to this variant employs a pair of inwardly and opposingly facing mandrels  48  and  50 . One or both of the mandrels  48  and  50  are capable of being actuated inwardly and outwardly and each further includes a substantially cylindrical projection, see at  52  for mandrel  48 , as well as at  54  for mandrel  50 . The cylindrical projections  52  and  54  are likewise arranged in opposing fashion and along a common axis so that, during bending/shaping operations, they provide a support for the associating beams  44 ′. 
     One or both of the mandrels  48  and  50  each includes a short cylinder, see at  49  for mandrel  48 , as well as a same short cylinder for mandrel  50  (not showing in illustrations). Both short cylinders,  52  and one at mandrel  50  (not shown) are likewise arranged in opposing fashion and along a common axis so that, during bending/shaping operations, they provide a support for the associating edges  40  and  42  of the spring cage blank  18 . As best illustrated, the projections  52  and  54  each further include inwardly/downwardly sloping and annular extending walls and which assist in establishing the desired end configuration of the spring cage. 
     Referring to FIG. 3A, an initial operating station, illustrated generally at  56 , and in which female die (illustrated partially  58 ) is employed for providing an initial stamping configuration to the curved beams  18 ′. As previously described, the provision of the spring clip blanks  18 ′,  20 ′ et seq., in plurality fashion and supported upon the carrier strips  22  and  24  permits a successive and relatively high speed operation to be performed in which the spring cages are quickly and successively form shaped into the desired configuration  18 ′. 
     The female die  58  includes a specified inwardly radial configuration  60  such that, in an initial forming operation, a first semi-shaping configuration (again FIG. 3A) is imparted to the spring cage  18 ′. It is also envisioned that a pair of opposing female dies can be provided on opposite facing (upper and lower) sides of the mandrel and spring cage assembly (see also variants of FIGS.  4  and  5 ), with the exception of having a different inwardly radial configuration (see again at  60 ). 
     For each succeeding operating station, see at  62  for FIG. 3B, at  64  for FIG. 3C and, finally, at  66  for FIG. 3D, progressively configured female dies (either singularly or in pairs) may be provided (although not shown) for successively shaping the spring cage until it achieves its desired configuration, the hourglass shape,  18 ′ (FIG. 3D) which substantially replicates the illustration of FIG.  7 . 
     FIG. 3C, corners  68  and  70  of the joint end  42  are offset in axial direction and in which the corner  70  is forward and the corner  68  is backward, and further such that end  42  is now arranged in helix fashion, as is joint end  40 . Ideally, the corners  68  and  70  must also be at same plan and which is caused forces exerted by the angular beams  44 ′ and material mechanical resistance. The use of the mandrels at each forming station minimizes the offset of the corners  68  and  70  at joint end  42  as well as at other joint end  40 . 
     In a final of the successive forming operations, and referring specifically to FIG. 3D, a turning-slide shape  71  is incorporated into the right side of mandrel  48 . Additionally, a mirrored turning-slide shape (only partially illustrated at  71 ′) is arranged at the left side of mandrel  50 . Opposite joining ends of the right half (or less than half) at first extending edge  40  and the left half (or less than half) at second extending edge  42  are over-flexed in opposite axial directions by the shaping forces exerted by the two turning-slide shapes  71  and  71 ′ when the mandrels  48  and  50  move inward. 
     The purpose of the over-flexing is in order to establish an on-plane configuration (meaning corners  68  and  70  are on same plan at end  42 , same fashion at other end  40 ) during subsequent material spring-back and which is associated with the tensioned copper spring cage construction. The distance of over-flexing is pre-calculated according to material properties. 
     It is also envisioned to be within the scope of the invention that a plurality of individual pairs of actuable mandrels ( 48  and  50 ) be employed (such as for each succeeding operating station in FIGS. 3A,  3 B,  3 C and  3 D). Alternatively, a standard pair of mandrels and cylindrically projecting forming surfaces may be provided and, instead, alternating and/or progressively configured female dies may be transferred in succeeding fashion to provide the necessary forming/shaping operations of the spring cage  18 . 
     Referring now to FIG. 4, a further variant is illustrated at  72  of a single stage forming operation of the associated spring cage  18 ′ and which again includes such elements as first and second mandrels  74  and  76 , as well as associated and curving cylindrical projections  78  and  80 . The projections  78  and  80  are configured to match the inner annular configuration of the corresponding ends of the spring cage during forming and provide a support shoulder or surface to each of the corresponding edges  40  and  42  of the spring cage blank  18 ,  20 , et seq., during formation into its ultimate hourglass shape  18 ′ inside of the formed cage. As previously described, the mandrels  74  and  76  and associated projections are mounted in axial and inwardly/outwardly actuating fashion and in order to work in conjunction with an assembly line process by which the elongated carrier strips  22  and  24  transfer each of a succeeding plurality of the spring cage blanks to the operating station  72 . 
     A pair of opposing and inwardly actuating dies  82  and  84  are provided and in order to define the substantially cylindrically-configured spring cage, in a single forming/stamping operation, with an “hourglass” shaping to the outside surfaces of the substantially formed cage  18 ′. This shaping is assisted by female configured surfaces  86  and  88  (corresponding to dies  82  and  84 ) and which in particular define the negative impression of the hourglass shape (see also FIG. 4A cutaway). 
     Referring further to FIG. 5, an alternate forming operation is illustrated at  90  and which is substantially similar to that previously described at  72  in FIG.  4 . The variant  90  of FIG. 5 does differ in the manner in which the opposing and mating dies  92  and  94 , and in particular their corresponding and opposing negative impression surfaces  96  and  98 , are configured. The dies  92  and  94  of FIG. 5 provide a somewhat enlarged and consistent radial profile (see as opposed to substantially hourglass shaped dies  82  and  84  in FIG. 4) and in order that the configured spring cage blank  18 ′ acquires the ultimately cylindrical shape without the additional “hourglass” configuration at this stage. The projections  78  and  80  of mandrels  74  and  76 , respectively, can additionally be either taper shaped as shown or cylindrical shape. 
     Referring now to FIG. 6, a further forming operation is illustrated at  100 , typically employed subsequent to the initial stamping operation of FIG. 5, and which completes the configuration of the previously and substantially cylindrically shaped spring cage blank  18 ′ with a desired hourglass configuration. As with the description of FIG. 5, the configuration of the spring cage blank  18 , mandrels  74  and  76  and associated shoulder projections  78  and  80  in FIG. 6 are again repeated and may again be part of a same operating station as utilized with the mating dies  92  and  94 . The additional forming/operating station  100  of FIG. 6 does also include the provision of first ( 102  and  104 ) and second ( 106  and  108 ) pairs of opposing and inwardly actuable forming dies and it is understood that these are transferred into contact with the cylindrically formed spring cage following the stamping procedure of FIG.  5 . 
     The first pair of forming dies  102  and  104  encircle and are inwardly actuable abut in proximity to the first extending end or edge  40  of the spring cage, the second pair of forming dies  106  and  108  likewise encircle and abutting the second extending end  42 . Each of the forming dies  102 ,  104 ,  106  and  108  further includes a plurality of teeth arranged in corresponding and semi-circular patterns for securely gripping the edges  40  and  42  of the substantially cylindrically formed spring cage following operation in FIG.  5  and in proximity to the spaced apart beams  44 . Reference is made specifically to semi-circular/radial teeth patterns  110 ,  112 ,  114  and  116  and which correspond, respectively, with each of the succeeding forming dies  102 ,  104 ,  106  and  108 . 
     Upon both pairs  110  &amp;  112  and  114  &amp;  116  of the forming dies being inwardly actuated in gripping fashion about the corresponding ends  40  and  42  of the sleeve, either or both pairs  102  and  104  are rotated a selected angle in a direction consistent with the angle  46  established by the beams  44 ′. In a preferred variant, and upon rotation of the selected cage end (such as at  40 ), the associated connection  28  is cut off (see as best shown in FIG.  6 ), after which the operation performed in FIG. 5 is commenced and the end  40  is thus free to be rotated. 
     In the preferred variant, the first pair  114  &amp;  116  of the forming/gripping dies are rotated (the second pair  110  &amp;  112  of forming/gripping dies remaining fixed) in an angular direction ranging from between 12 to 18 degrees (an ideal configuration being a 15° imparted angle) relative to the second pair of forming dies. Following the torsional/twisting operation, the completed spring cage  18 ′ is sectioned from the carrier  24  (via the connecting web portions  30 ). In this manner, the substantially hourglass shaping is imparted to the previously cylindrically formed configuration of the spring cage at the operation illustrated in FIG.  5  and in order to provide enhanced gripping and biasing characteristics within the socket assembly  10  as will be shortly described in more detail. 
     Referring again to FIGS. 8 and 8B, a substantially tubular shaped and interiorly hollowed sleeve  118  is illustrated in use with the present invention and which forms a component of the assembleable and terminal socket assembly  10 . The sleeve  118  may, similarly to the assembled spring cage  18 ′, be formed of a tensioned copper material and, referring further to FIG. 8A, it is contemplated that the sleeve  118  may also be initially provided as a blank shape configuration, supported between carrier strips  120  and  122  transferable by apertures  124  formed there along their axial lengths, and connected to the strips  120  and  122  by webbed/connecting portions  126  and  128 . As with the illustration FIG. 1 of the spring cage blanks  18 ,  20 , et seq., a plurality of individual and spaced apart tubular sleeves  118  may be provided along the carrier strips  120  and  122  and which are subject to an appropriate stamping/die forming operation for assembling into the desired shape again referenced in FIGS. 8 and 8B. 
     Referring again to FIGS. 8,  8 A and  8 B in particular, the tubular sleeve  118  of the illustrated and preferred variant includes gripping portions in the form of spaced apart pairs  130  and  132  of tabs which, upon inserting the appropriate end of the existing vehicle cable  14 , are bent or actuated in the manner indicated to fixedly engage and electrically communicate the cable  14 . As is also illustrated from the blank layout of FIG.  8 A and the cutaway of FIG. 10, an inner base surface of the sleeve  118  corresponding to the pair  130  of tabs includes a plurality of lateral extending and spaced apart grooves  131 , the purpose for which being to provide additional gripping capacity to the coils extending from the cable  14  once the tabs  130  and  132  have been actuated (see arrows in FIG. 8) and to the fixing location of FIG.  8 B. The male pin  12  may also include, without any limitation, a configured end with a lead chamfer, as illustrated, which is ideally suited for exerting a correct pressure/friction mating with the biasing interior of the assembled spring cage and sleeve. 
     The tubular sleeve  118  further includes a substantially axially extending and slitted incision which defines first  134  and a second  136  opposing and predetermined spaced apart edges. The edges  134  and  136  are further defined, in one preferred variant, by an alternating keyed pattern (see at  138  for edge  134  and at  140  for edge  136 ). Keyed alternating projecting and recessing keyed portions defined by these patterns meshingly engage one another, upon assembly of the sleeve  118  and in the manner shown in FIG. 8, and so that a pretermined and incremental spacing, see also at  142 ,  143  and  144 , exists between the mating and opposing edges  134  and  136  and, to a lesser extent, around and along the alternating keyed projections and recesses. The incremental spacing is created by not fully closing the key stone edges  138  and  140 , such that edges  134  and  136  are maintained at a calculated and slightly spaced apart position. 
     An aspect of the terminal socket assembly  10  is the ability to pressure and frictionally engage the formed spring cage  18 ′ within the sleeve  118 , upon completed assembly, and this is performed by initially inserting the cage  18 ′ into an axial and open end of the sleeve  118 . Referring to FIG. 9, a single pin  148  (or pair of opposite pins  146  and  148  arranged in opposite arraying fashion) may be employed to axially insert the cage  18 ′ into the tubular sleeve  118  through the force (linear or opposing) exerted by shoulders  143  and  145  which define narrowed projecting portions  145  and  149  of the pins  146  and  148 , respectively. Typically, the exterior diameter of the cage  18 ′ is an incremental amount lesser than a corresponding inner diameter of the tubular sleeve  118  and in order to permit the spring cage  18 ′ to be easily inserted during assembly and because the incremental spacing is created by not fully closing key stone edges  138  and  149  extending or recessed into the associated edges  134  and  136 . 
     The leading portions  147  and  149  in the tool pins  146  and  148 , respectively, are engaged inside with cage ends  42  and  40  in FIG.  10 . In a subsequent forming operation, a pair of mating dies  150  and  152  (having corresponding and opposing mating female surfaces  154  and  156  according to specified radii) compressingly engage and inwardly actuate the sleeve  118  about the installed spring cage  18 ′. In this fashion, the inner diameter of the sleeve is decreaded (by virtue of closing the spacing indicated at  142 ,  143  and  144 ), thereby frictionally and permanently engaging the spring cage  18 ′ within the sleeve  118 . 
     The outer diameters of oppositely inserted leads (see at  147  and  149  in FIG. 10) are dimensioned to equal the final diameter of the finished sleeve assembly. During insertion forming (crushing), the sleeve and closing the space  142 ,  143  and  144 , the leads  147  and  149  help to avoid cage ends  40  and  42  clapping and also to hold the specified finish diameter. The dimensions of the perimeters of cage ends  40  and  42  are calculated such that seams on each end of  40  and  42  are in tight contact (for example, reference corners  68  and  70  arranged in tight contact in FIG.  3 C). In this fashion, significant amount of pressure between cage ends ( 40  and  42 ) and the sleeve is built during die crushing the sleeve. 
     Referring again to FIG. 10, a pointed tool  158  may be axially displaced to “flare out” one or more annular end location  160   s  of the tubular sleeve  118  and in order to provide additional (typically secondary) retaining force to the previously assembly and compressed terminal socket assembly. A lance  161  may also be defined upon the inside surface, near the mid to rear end of the sleeve (proximate the gripping portions  130 ) and provides an additional type of secondary holding force by limiting the forward movement of the cage  18 ′ once it has been inserted into the sleeve  118 . 
     Referring now to FIG. 14, a further valiant  162  of a tubular sleeve is illustrated and which includes first  164  and second  166  open ends. A pair of gripping portions  168  define a portion of the sleeve  162  and extend in substantially angular (typically 90° fashion) relative to the axial direction of the inserting sleeve. Inserting pins  172  and  173  may again be utilized in linearly arranged and opposingly engageable fashion to assemble the spring cage (not shown) into the sleeve  162 , typically through associated first open and inserting end  164  and in similar fashion as to that previously described in FIG.  9  and FIG.  10 . It is also contemplated that all assembly processes, blanking and forming sleeve  118  are built into same progression die. 
     Referring now to FIGS. 11,  12 , and  13 , in succession, a variety of assembly variants are illustrated according to additional aspects of the present invention. Referring first to the illustration  174  of FIG. 11, a variation of the sleeve is illustrated at  176  and which is in the form of a tube or bottle with a first end  178  and a second end  180 . The second end  180  is considered a bottom of the tube or bottle shape. The opposite edges  40  and  42  of the configured spring cage  18 ′ are dimensioned so that the first edge  40  establishes a smaller diameter than a corresponding inner diameter of the sleeve  176 , whereas the second edge  42  establishes a slightly larger diameter. The first edge  40  with the smaller diameter is inserted first into the sleeve  176 , following which the opposite edge  42  exhibiting the larger diameter is successively inserted in pressure-fitting fashion. 
     An eyelet terminal  182  is provided and which includes angular (again preferably 90° extending) gripping portions  184  and  186 . An aperture  188  is typically formed through a base of the eyelet terminal  182  and an O-ring  190  is provided which, upon pre-assembly of the spring cage  18 ′ into the sleeve  176 , is sandwiched between an inner configured surface  192  of the eyelet terminal  182  and the corresponding first end  178 . The eyelet terminal  182  is then friction fitted into tube  176 . Upon assembly, the eyelet terminal  182  defines an overall component of the socket assembly and provides a sealed terminal. 
     Referring to FIG. 12, a subsequent variant is illustrated at  194 , largely repeating that previously identified in FIG. 11, and in which an unsealed variant of the terminal is established by deleting the O-ring  190 . Otherwise, the spring cage  18 ′ is assembled into the tube variant  176  of the sleeve in similar fashion and so that the gripping portions  184  and  186  extend in the desired angular relationship and so that they can grasp the associated extending end of a cable to be electrically communicated with the terminal socket assembly. 
     Referring to FIG. 13, a yet further variant  198  of a terminal socket assembly is illustrated and which includes an alternate configuration  200  of a tubular shaped member, which in turn includes an internal receiving sleeve portion  202  (for axially receiving the configured spring cage). The spring cage  18 ′ is further dimensioned so that it exerts the slightest of an interference fit with the interior of the sleeve portion  202  upon inserting the cage  18 ′. Application of a subsequent compressing force creates the necessary resistance fit of the cage within the tubular sleeve. The illustration  198  additionally illustrates that the terminal socket assembly can be configured in either straight or angled applications and the manner in which the cage  18 ′ is inserted into the sleeve member  200  can again be drawn from any existing variant known in the art. 
     Referring finally to FIGS. 16 and 17, two examples of connector housing assemblies are illustrated and which may be utilized with any of the afore-described terminal socket assemblies according to the present invention. It should also be noted that the connector housing assemblies provide additional sealing and insulating characteristics to the underlying terminal socket assembly, when employed in a given vehicular application, however the presence of a given type of housing assembly is not necessary according to the broadest dictates of the present invention. 
     Referring again to FIG. 16, an illustration is presented of a substantially “T” shaped and sealed connector housing  208  according to the present invention. An associated terminal socket assembly is further illustrated at  210  (see also FIG. 15) and again presents a sleeve  212 , within which is installed an appropriately configured spring cage  18 ′. Compression forming of the cage  18 ′ within the sleeve  212  is further provided by a slit  214  defined between corresponding axial surfaces of the sleeve  212 . Bracket portions  216  and  218  integrally extending from the opposing edge locations of the sleeve. At least one button (and illustrated in FIG. 15 as a pair of buttons  220 ) is arranged upon the bracket portions  216  and  218  in engageable fashion and, upon being depressed, compressingly engages the inner diameter of the sleeve about the spring cage. As will be subsequently described in additional detail, the buttons  220  are further configured so that they will lock into place and to retain the desired friction engaging relationship between the sleeve and spring cage. The locking between  216  and  218  can be done in other fashions such as welding and riveting. Additionally, gripping portions  222  are provided in integrally extending fashion from an end of the bracket portion  218  and enable an associated cable end to be secured in a substantially perpendicular manner relative to the extending direction of the sleeve  212 . 
     Referring to FIG. 15A, a side cutaway view is illustrated of a “T” shaped terminal assembly, such as shown in FIG. 15, and illustrating in side cutaway a first interengaging configuration of the extending bracket portions  216  and  218  and buttons  220 . In particular, and as is evident in the side cutaway illustration, the button portions  220  are formed by a die stamping or other suitable forming operation and such that the stamped or otherwise formed portions  219  and  219 ′ are compressed and flattened in the manner illustrated to define button(s) in the form of dual mushroom shapes in the manner illustrated. In this fashion, the biasing engagement of the bracket portions  216  and  218  about the sleeve  212  and inserted spring cage  18 ′ is maintained. 
     Referring further to FIG. 15B, a side cutaway view is shown of a further variant of a “T” shaped terminal assembly, similar to that previously shown in FIG.  15 . According to this variant, a further engaging configuration of the buttons, again generally referenced at  220 , is established by extending portions  223  (as again illustrated in the side cutaway) from selected bracket portion  218  and which project through apertures (see inner annular walls  225 ) defined in aligning portions of the other selected bracket portion  216 . A top of extending portion  223  is compressed such that the annular edge portions (see at  227 ) of the extending portions are slightly flattened against the corresponding upper surface of the bracket portion  216  and in order to firmly bias towards each other the bracket portions  216  and  218 , and thereby firmly compress the inner diameter of the sleeve  212  about the inserted spring cage  18 ′. 
     Referring to FIG. 15C another side cutaway view is shown of a “T” shaped terminal assembly according to a further preferred variant of the present invention. In this variant, the button portions (previously identified at  220  in FIGS. 15A and 15B) are substituted by a weld  229  formed along a trailing edge of the bracket portion  216  and an underlaying and adhering surface of the bracket portion  218 . In an alternate configuration, the bracket portions are welded in a middle region to form a firm joint  221  of the bracket portions  216  and  218 , this further typically being accomplished by ultrasonic welding or resistance welding. In this fashion, the bracket portions  216  and  218  are again biased towards each other, and thereby firmly compress the inner diameter of the sleeve  212  (from which they integrally extend) about the inserted spring cage  18 ′. 
     FIG. 15D illustrates a side cutaway view of a “T” shaped terminal assembly according to a still further preferred variant of the present invention. In this variant, a further mechanism for biasing the integrally extending bracket portions  216  and  218  towards each other includes, as once again illustrated in side cutaway, an angled/bent finger portion  231  (or pair of spaced apart portions) and incorporating material drawn from the extending bracket portion  216 . The finger portion  216  extends through an aligning recess (or recesses) in the corresponding bracket portion  218  and which is defined in the FIG. 15D side cutaway by inner annular extending wall  233  defined in the bracket portion  218 . A rivet (or pair of rivets)  235  are provided for securing the downwardly extending ends of the finger portion(s)  216  in inwardly biasing and seating fashion through the apertures and again in order to biasingly compress the inner diameter of the sleeve  212  about the inserted spring cage  18 ′. 
     FIG. 15E illustrates a side cutaway view of a “T” shaped terminal assembly according to a still further preferred variant of the present invention. In this variant, a further mechanism for biasing the integrally extending bracket portions  216  and  218  towards each other includes, as once again illustrated in side cutaway, at least one rivet  237  having a specified three-dimensional shape and projecting through apertures  239  and  239 ′ from bracket portions  216  and  218 , respectively. A top  241  and bottom  241 ′ of the rivet  237  is compressed such that associated annular edge portions (see at  243  and  245 ) of the rivet are slightly flattened against the corresponding upper surface of the bracket portion  216  and lower surface of the bracket portion  218 , respectively, and in order to firmly bias towards each other the bracket portions  216  and  218 , and thereby firmly compress the inner diameter of the sleeve  212  about the inserted spring cage  18 ′. 
     Referring again to FIG. 16, the overall housing/sealing assembly is again shown and includes a female housing  224  having at least a first  226  and a second  228  open and inserting end established at an angle relative to one another. The female housing  224  defines an open interior for receiving, through the first inserting end  226  and in the manner illustrated, the socket assembly  210 , incorporating again the sleeve and interiorly installed spring cage. The gripping portions  222  again extend at an angle relative to the inserting sleeve portion  212 , in proximity to the first inserting end  226 , and for engaging the cable (such as illustrated at  14  in FIG. 8) within the first inserting end  226 . 
     An elongate and internally hollowed male housing, is illustrated generally at  230 , having first  232  and second  234  opposite and open ends. The male housing  230  is engageable with female housing  224  through the opening  228 , such that the second end  234  is fully passed through opening  228  of housing  224 . The hollow of the male housing  230  is then jacked over “T” terminal sleeve  212 . This male housing  230  is locked into female housing  224  through the application of locking fingers (not shown). Upon locking, the male housing  230  is fixed inside female housing  224  and the “T” terminal assembly is fixed and maintained in its desired position. The male housing  230  is usually called terminal position assurance. In application, a male pin (corresponding to male pin  12  in FIG. 8) is biasingly engaged with the assembled sleeve and spring cage  210  contained within the female housing  224 . 
     Additional sealing components include a grommet  236 , engageable over the open first inserting end  226  of the female housing  224  and including a grommet retainer  237  with central aperture  239  through which may extend the connecting cable  238 . Additional elements include a interfacial seal  240  and seal retainer  242  which are ultrasonically welded to the second inserting end  228  of the female housing  224 , and thereby retained in place. 
     Referring finally to FIG. 17, an alternate housing assembly is illustrated at  248  and which provides a 90 degree (as opposed to “T” shape) sealing arrangement about a previously assembled terminal socket assembly, such as previously disclosed at  162  in FIG.  17 ). The housing assembly of FIG. 17 largely replicates the construction arrangement previously set forth in the assembly  208  of FIG.  16  and includes a female housing  250  having a first  252  and a second  254  open inserting end established at a perpendicular angle relative to each other. The female housing  250  again defines an open interior for receiving the assembled sleeve and interiorly installed spring cage assembly  162 . In this variant, the female connector  250  may be provided in halves (not shown) which are assembled over the socket assembly  168  and ultrasonically welded at an intermediate step. 
     As with the previous embodiment, the gripping portions  168  of the socket assembly  162  extend at an angle relative to the corresponding sleeve  164 . A grommet retainer  270  and subsequent grommet  271  are slid over cable  256 . Following this, the cable  256  is then pushed through the “elbow shaped” female housing  250 . The cable copper wire end  258 , is then crimped to gripping portion  168  of the assembly  162  in the fashion also illustrated at  130  shown in FIG.  8 B. Following this, the cable  256  is withdrawn in reverse pulling fashion back through the female housing  250 , such that the 90 degree terminal assembly  162  is likewise withdrawn into the female housing  250 , and further so that the gripping portions  168  reach the end  254  of housing  250 . The gripping portion  168  is purposely designed such that it easily passes the 90 degree turning of the “elbow shaped” housing  250 . Following the same fashion previously set forth in FIG. 16, the grommet  271  and grommet retainer  270  (not shown in FIG. 17) are assembled to end  254  of the female housing  250 , a terminal position assurance  255  is locked into the housing  250  and to position the terminal assembly  162 , and seal  256  and seal and retainer  259  are assembled and ultrasonically welded to the end  252  of female housing  250 . 
     The present invention therefore discloses an improved terminal socket assembly having reduced number of component, minimized joints through electrical power path from male pin through cable at sleeve end which, therefore, increased effective contact area through the electrical power path compared to prior art type pin terminals. The forming process in progression die is used for making cage into hourglass shape. All assembly processes, blanking and forming sleeve  118  are built into same progression die. The use of progression die carriers (see again variants of FIGS. 3A-3D through FIG. 6) in an automation process provides greater economies of scale in manufacture of the socket assemblies. 
     The socket assembly is also constructed of a simplified two-piece component arrangement and has been found to require less material and forming operations than other conventional assemblies. Finally, the terminal socket assembly has been found to be cost effective in both low and high current applications and can be used to replace existing nut and bolt power connection systems, thus eliminating torque or cross threading problems. 
     Having described the presently preferred embodiments, it is to be understood that the invention may be otherwise embodied within the scope of the appended claims.