High power single-pole electrical connector

1. A single-pole electrical connector, comprising:

a. a core conductor, having a contact end, a cable end, and a retaining groove positioned between the contact end and the cable end;

b. a rigid core region insulator positioned radially outward of the core conductor and extending from a point near the retaining groove toward the cable end;

c. a rigid contact region insulator positioned radially outward of the core conductor and extending from a point at or near the contact end to a point near the retaining groove;

d. an insulating axial positioner located between the rigid core region insulator and the rigid contact region insulator, the insulating axial positioner having a radially inner side and a radially outer side, the radially inner side inserted in the retaining groove of the core conductor; and,

e. a shell positioned radially outward of the rigid contact region insulator.

2. The connector of claim 1 , wherein the insulating axial positioner is flexible.

3. The connector of claim 1 , further comprising a barrel positioned radially outward from the cable end of the core conductor, the barrel configured to be secured to the shell such that the insulating axial positioner is compressed.

4. The connector of claim 3 , wherein the compression of the insulating axial positioner creates a water tight seal at the core conductor and at the shell.

5. The connector of claim 3 wherein the barrel and shell are threaded.

6. The connector of claim 1 , further comprising a barrel positioned radially outward from the cable end of the core conductor, and an insulating sleeve positioned within a recess in the barrel.

7. The connector of claim 6 , wherein the insulating sleeve is positioned such that when the connector is secured to a power cable having a conductive core, the insulating sleeve is between an exposed part of the cable conductive core and the barrel.

8. The connector of claim 5 , wherein the core conductor is sized to be compatible with size 646 mcm cable and the shell and barrel are size 20 components.

9. The connector of claim 8 , wherein the connector is rated for at least 1,000 A.

10. The connector of claim 5 , wherein the core conductor is sized to be compatible with size 777 mcm cable and the shell and barrel are size 20 components.

11. The connector of claim 1 , further comprising

a. a barrel positioned radially outward from the cable end of the core conductor, the barrel having a compression shoulder; and,

b. a retaining lip at the contact end of the shell, wherein the compression shoulder engages with an end of the rigid core region insulator and the retaining lip engages with an end of the rigid contact region insulator, such that when the barrel is secured to the shell, the retaining lip and compression shoulder exert force against the rigid contact region insulator and the rigid core region insulator, respectively.

12. The connector of claim 1 wherein the difference between the inside diameter of the rigid contact region insulator and the outside diameter of the contact end of the core conductor is less than 2 mm.

13. A high-power, single-pole electrical connector, comprising:

a. a core conductor having a contact region, a mid region, and a cable end region, the mid region having a retaining groove;

b. a first insulator positioned around the contact region of the core conductor;

c. a second insulator positioned around at least part of the mid region of the core conductor; and,

d. a flexible, insulating axial positioner inserted in the retaining groove of the core conductor and positioned between the first and second insulators.

14. The connector of claim 13 , further comprising an outer casing positioned radially outward of the first and second insulators and the insulating axial positioner.

15. The connector of claim 13 , further comprising an outer casing and wherein either the first or second insulator is an integral part of the outer casing.

16. The connector of claim 13 , wherein the difference between the inside diameter of the first insulator and the outside diameter of the contact region of the core conductor is less than 2 mm.

17. A method of assembling a high-power, single-pole electrical connector comprising the following steps, though the sequence of steps may vary:

a. inserting an insulating axial positioner into a retaining groove in a core conductor;

b. inserting a first rigid insulator into a shell;

c. inserting the core conductor into the first rigid insulator, such that the insulating axial positioner is in contact with the first rigid insulator;

d. inserting a second rigid insulator into the shell;

e. securing a barrel to the shell, such that the first and second rigid insulators compress the insulating axial positioner.