Battery disconnectors made from flame-retardant PA6/6.6 blend
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Safety in an emergency thanks to flame-retardant PA6/6.6 blend
Pyrotechnic battery disconnector based on a 30% glass fibre-reinforced, flame-retardant and heat-stabilised PA6/6.6 blend – developed for maximum safety and long-term durability in high-voltage electrical systems.
A pyrotechnic battery disconnector is a safety-critical component in e cars. In an emergency, it ensures reliable, rapid interruption of the circuit by means of controlled pyrotechnic tripping. When triggered, a plastic projectile is shot with an explosive charge inside the flame-retardant housing and breaks. A pre-punched copper part with a wall thickness of over 2 mm is then securely clamped in the housing. This all happens in milliseconds, e.g. during the first rollover, and guarantees safe disconnection of the circuit. This protects the driver and later also the emergency team.
The choice of materials as well as mechanical and electrical safety are of central importance for this application. The compound AKROMID® C3 GF 30 1 FR black (7243), a 30 % glass fibre reinforced, flame-retardant and heat-stabilised PA6/6.6 blend, ensures sustainable solutions that meet the demanding standards of the automotive and energy industries.
Requirements for pyrotechnic battery disconnectors
Pyrotechnic battery disconnectors must fulfil extreme environmental conditions, high current loads and strict safety requirements. The materials used guarantee
Flame retardant (V0 according to UL 94)
High mechanical strength
Long-term heat ageing resistance (G2, 50,000 hours)
For OEMs and suppliers in particular, these properties are a decisive factor in the design process.
Innovation category
Winner of the SPE Awards 2025
The component impressed the almost 40 members of the SPE jury so much that it was honoured with the Innovation Award 2025.
Properties of the flame-retardant PA6/6.6 blend
AKROMID® C3 GF 30 1 FR black (7243) combines excellent flame-retardant properties with high structural stability and proven long-term resistance to heat and ageing. The following overview shows the key properties:
Flame resistance
UL 94 V0, self-extinguishing
30 % glass fibre reinforcement
High strength, rigidity
High tracking resistance
Chemical resistance
Resistant to electrolytes
Heat resistance
High continuous service temperature
Heat ageing
G2 classification (50,000 hours)
Relevant standards and regulations
The UL listing (Underwriters Laboratories) confirms that the material used and the components made from it meet strict, internationally recognised safety standards. For electronic safety components in high-voltage systems - such as pyrotechnic battery disconnect switches - UL certification is practically indispensable for market authorisation and exportability, particularly to North America.
UL-approved plastics and components minimise risks such as fire, electric shock or mechanical failure under load.
The certification is based on comprehensive testing of flame retardancy, electrical behaviour, heat and ageing resistance, mechanical integrity and chemical resistance.
For manufacturers, an existing UL listing means a seamless certification process for the entire product, as all relevant components and materials already demonstrate compliance with UL standards.
Plastic compounds with a UL listing offer maximum planning security and accelerate project processing for OEMs and system suppliers.
The Thermal ageing resistance is a key factor for components that have to reliably fulfil their function over many years in environments with elevated temperatures. The G2 classification (typically 50,000 h at an elevated test temperature) certifies that the material largely retains its mechanical properties even after long-term thermal stress.
Heat ageing testing is carried out in standardised hot air ovens under defined temperature and time conditions:
Material samples are exposed to an elevated temperature for defined periods of time (e.g. 5,000, 20,000 or 50,000 hours).
Type tests - such as tensile strength, elongation at break and notched impact strength - are carried out at regular intervals.
The values obtained are compared with the initial properties. A successful classification (such as G2, 50,000 h) confirms that the material does not exhibit any critical ageing degradation in the intended period of use.
Especially in safety-critical applications with a service life of at least ten years, this material verification is mandatory. This significantly reduces the risk of component failure, scorching or fire.
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Our component in focus
The targeted combination of glass fibre-reinforced, flame-retardant and heat-ageing-resistant PA6/6.6 blend not only makes battery disconnectors safer, but also supports weight reduction and process cost efficiency compared to metallic materials. Thanks to excellent formulation, precise, thin-walled structures can be realised that combine stability and electrical insulation. This is particularly essential for the reliable protection of electrical systems in the event of a fault.
Left: the components individually, Right: component group assembled
Detailed view of component group
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Our portfolio of flame-retardant compounds
We will find the right product for you from our flame-retardant portfolio:
AKROMID® A / B / C FR: flame-retardant PA 6.6, PA 6, PA 6.6/PA 6 blend
AKROMID® T91 FR: flame-retardant PA 9T
AKROTEK® PK FR: flame-retardant polyketone
AKROLOY® PARA FR: flame-retardant polyarylamide
PRECITE® P FR: flame-retardant PBT
PFAS-free flame retardant compounds
The products listed below are free from red phosphorus, halogenated flame retardants, antimony trioxide, zinc borate and PFAS-containing anti-drip agents. Innovative and future-proof!
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Disclaimer: All information provided on this website is based on our current knowledge and experience. A legally binding assurance of certain properties or suitability for a specific individual case cannot be derived from our information. Our information does not exempt processors and users from carrying out their own tests and trials for specific applications. AKROMID®, AKROLEN®, AKROLOY®, AKROTEK®, ICX®, PRECITE® and DIA(hr)LOG® are registered trademarks of AKRO-PLASTIC GmbH.
