Process of producing slit-formed sleeve connector

Abstract

A process of producing a slit-formed cylindrical sleeve connector for press-fitting and joining thin wires or thin rods, rigid or elastic, together in close or contacting relationship using an electroforming process that includes providing a thin conductive electroforming mandrel having an external surface finished to a specified grade of surface finish, forming a given pattern of nonconductive layer so as to define at least one cylindrical but circumferentially discontinuous electrodeposition cell on the electroforming mandrel electrodepositing an electroformed metal layer in the electrodeposition cell on the electroforming mandrel by an electroforming process, and removing the electroformed metal layer from the electroforming mandrel, thereby providing a cylindrical metal tube formed with a longitudinal slit as a slit-formed cylindrical sleeve connector having an internal wall with the same grade of surface finish as the external surface of the mandrel.

What is claimed is:  
     
         1 . A process of producing a slit-formed cylindrical sleeve connector in which a thin round string member is press-fitted using an electroforming process, sand process comprising the steps of: 
 providing a cylindrical mandrel made up from a conductive metal string member having an external surface finished to a specified grade of surface finish;    forming a given pattern of nonconductive layer which defines at least an electrodeposition cell on said cylindrical mandrel, said electrodeposition cell being cylindrical but circumferentially discontinuous;    electrodepositing a specified thickness of electroformed metal layer in said electrodeposition cell on said cylindrical mandrel by an electroforming process; and    removing said electroformed metal layer from said cylindrical mandrel, thereby providing a cylindrical metal tube slit in a longitudinal direction as a slit-formed cylindrical sleeve connector having an internal wall with the same specified grade of surface finish as said cylindrical mandrel.    
     
     
         2 . A process of producing a slit-formed cylindrical metal sleeve connector as defined in  claim 1 , wherein said electroforming process is controlled so as to provide said electroformed metal layer with a specified internal stress that is zero or compressive.  
     
     
         3 . A process of producing a slit-formed cylindrical metal sleeve connector as defined in  claim 1 , wherein said given pattern of non-conductive layer comprises circumferential annular segments separated at a specified distance in said longitudinal direction and a longitudinal segment extending between said circumferential annular segments.  
     
     
         4 . A process of producing a slit-formed cylindrical metal sleeve connector as defined in  claim 3 , wherein each said circumferential annular segment having outwardly chamfered or rounded side walls at opposite side edges.  
     
     
         5 . A process of producing a slit-formned cylindrical metal sleeve connector as defined in  claim 1 , wherein said uniform thickness of electroformed metal layer is electrodeposited on said cylindrical mandrel in an electrolytic fluid comprising a solution of nickel sulfamic acid.  
     
     
         6 . A process of producing a slit-formned cylindrical metal sleeve connector as defined in  claim 5 , wherein said electrolytic fluid contains naphthlin sodium trisulfoacid as an additive.  
     
     
         7 . A process of producing a slit-formed cylindrical metal sleeve connector as defined in  claim 4 , wherein said electrolytic fluid contains saccharin as an additive.