Terminals - Knife Connectors

Image	Part Number	Description / PDF	Quantity	Rfq
	8-35762-2 TE Connectivity AMP Connectors	CONN KNIFE TERM 10-12 AWG YELLOW	0
	FVDAH-2 JST	CONN KNIFE TERM 14-16 AWG BLUE	0
	FVDAH-5.5(LF) JST	CONN KNIFE TERM 10-12 AWG YELLOW	0
	DMV2-37MB-3K Panduit Corporation	CONN KNIFE TERM 14-16 AWG BLUE	0

Terminals - Knife Connectors

1. Overview

Knife connectors are a type of electrical terminal designed for high-current applications, featuring a blade-like contact structure. They enable rapid connection/disconnection while maintaining low contact resistance and high mechanical stability. These connectors are critical in power distribution systems, industrial machinery, and renewable energy equipment where reliable electrical conductivity and safety are paramount.

2. Major Types and Functional Classification

Type	Functional Features	Application Examples
Single-blade Knife Connectors	Simple design with a single conductive blade, suitable for low-voltage applications	Battery banks in UPS systems
Dual-blade Knife Connectors	Dual-contact design for higher current capacity and redundancy	Electric vehicle charging stations
Fuse-integrated Knife Connectors	Integrated fuse protection with visual disconnection point	Industrial motor controllers
High-voltage Knife Connectors	Designed for voltages >1kV with extended insulation gaps	Substation switchgear

3. Structure and Components

A typical knife connector consists of: - Contact Blade: Copper alloy or phosphor bronze with gold/silver plating for conductivity - Insulation Housing: Flame-retardant thermoplastic (e.g., PA66) or ceramic for high-voltage models - Retention Mechanism: Spring-loaded or screw-clamping system for secure mating - Terminal Interface: Screw terminals, compression lugs, or PCB-mount contacts

4. Key Technical Specifications

Parameter	Typical Range	Importance
Rated Current	10 500A	Determines power handling capacity
Contact Resistance	0.5 5m	Impacts thermal performance
Dielectric Strength	1 50kV	Safety isolation measure
Temperature Range	-40 C to +150 C	Environmental durability
Mating Cycles	500 5000 cycles	Long-term reliability indicator

5. Application Fields

Power Systems: Transformer tap changers, circuit breaker panels
Industrial Automation: PLC power distribution modules
Renewable Energy: Solar combiner boxes, wind turbine converters
Transportation: Electric vehicle battery interconnects
Telecom: High-current rectifier systems

6. Leading Manufacturers and Products

Manufacturer	Representative Product	Key Features
Phoenix Contact	UK Knife Connectors	Modular design, 400A rating
TE Connectivity	NanoMAX Series	Compact 150A connectors for EVs
ABB	PLT-KN Series	690V insulation, IP20 protection
WAGO	247 Series	Spring pressure technology, tool-free installation

7. Selection Guidelines

Key considerations include: - Current/voltage requirements with 20% safety margin - Environmental factors (temperature, vibration) - Compliance with standards (IEC 61984, UL 1977) - Maintenance accessibility - Cost-effectiveness for volume applications

Case Study: A 200kW solar inverter system selected dual-blade connectors with 500A rating to accommodate peak loads and ensure service life exceeding 10 years.

8. Industry Trends

Future developments focus on: - Miniaturization while maintaining high current density - Integration with smart monitoring sensors - Enhanced arc-resistant materials for EV applications - RoHS-compliant eco-friendly plating alternatives - Automated assembly-compatible designs