Full tension swaged connector
An improved full tension connector for electrical conductors has a substantially cylindrical outer surface and a stepped series of substantially cylindrical inner surfaces with progressively smaller inside diameters. The design of the connector allows for improved control of the compression of the cable inside the fitting. A series of swages, progressing successively from a light compression to a heavier compression, ensures that the connector will sustain the required tensile load.
1. A connector for an electrical conductor comprising:
a body having a substantially cylindrical outer surface;
a first substantially cylindrical inner surface having a first inside diameter d 1 , the first inner surface extending axially from a first end of the body to a depth A;
a second substantially cylindrical inner surface having a second inside diameter d 2 smaller than d 1 , the second inner surface extending axially from the depth A to a depth B;
wherein d 1 −d 2 <0.05″.
2. The connector of claim 1 further comprising a third substantially cylindrical inner surface having a third inside diameter d 3 smaller than d 2 , the third inner surface extending axially from the depth B to a depth C;
wherein d 2 −d 3 <0.05″.
3. The connector of claim 2 further comprising a fourth substantially cylindrical inner surface having a fourth inside diameter d 4 smaller than d 3 , the fourth inner surface extending axially from the depth C to a depth D;
wherein d 3 −d 4 <0.05″.
4. The connector of claim 1 wherein the body is configured as a splice.
5. The connector of claim 1 wherein the body is configured as a dead end.
6. A method of attaching the connector of claim 1 to an electrical conductor comprising:
inserting an electrical conductor into the connector to at least depth B;
compressing the outer surface of the connector between the first end and depth A with a first compression force;
compressing the outer surface of the connector between depth A and depth B with a second compression force greater than the first compression force.
7. A method of attaching the connector of claim 2 comprising:
inserting an electrical conductor into the connector to at least depth B;
compressing the outer surface of the connector between the first end and depth A with a first compression force;
compressing the outer surface of the connector between depth A and depth B with a second compression force greater than the first compression force; and
compressing the outer surface of the connector between depth B and depth C with a third compression force greater than the second compression force.
8. The method of claim 6 wherein the steps of compressing are performed using a swaging tool.
9. The method of claim 7 wherein the steps of compressing are perforated using a swaging tool.