Safety in Emergencies Thanks to Flame-Retardant PA6/6.6 Blend
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Winner of the Spe Innovation Award 2025
Safety in Emergencies Thanks to Flame-Retardant PA6/6.6 Blend
Pyrotechnic battery disconnect based on a 30% glass fiber-reinforced, flame-retardant and heat-stabilized PA6/6.6 blend – developed for maximum safety and long-term durability in electrical high-voltage systems.
A pyrotechnic battery disconnect is a safety-critical component in electric vehicles. In an emergency, it ensures reliable and rapid interruption of the electrical circuit through controlled pyrotechnic activation. During such an activation, an explosive charge is ignited inside a flame-retardant housing made from our plastic compound AKROMID® C3 GF 30 1 FR black (7243). A pre-punched copper component with a thickness of over 2 mm is then safely clamped inside the housing. The entire process takes place within milliseconds, for example in the event of an initial impact, and ensures reliable circuit disconnection even during subsequent impacts. This protects both the driver and the emergency services.
Material selection, along with mechanical and electrical safety, is of central importance in this application. AKROMID® C3 GF 30 1 FR black (7243), a 30% glass fiber-reinforced, flame-retardant and heat-stabilized PA6/6.6 blend, enables sustainable solutions that meet the demanding standards of the automotive and energy industries.
Requirements for Pyrotechnic Battery Disconnects
Pyrotechnic battery disconnects must withstand extreme environmental conditions, high electrical loads, and stringent safety requirements. The materials used must guarantee:
Flame retardancy (UL 94 V-0)
High mechanical strength
Long-term heat aging resistance (G2, 50,000 hours)
For OEMs and suppliers in particular, these properties are crucial factors in the design process.
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 aging. The following overview highlights its key properties:
Flame Retardancy
UL 94 V-0, self-extinguishing
30% Glass Fiber Reinforcement
High strength and stiffness
High Tracking Resistance
Chemical Resistance
Resistant to electrolytes
Heat Deflection Resistance
High continuous operating temperature
Heat Aging Resistance
G2 classification (50,000 hours)
Relevant Standards and Regulations
UL Listing (Underwriters Laboratories) confirms that the material used and the components manufactured from it meet stringent, internationally recognized safety standards. For electronic safety components in high-voltage systems – such as pyrotechnic battery disconnects – UL certification is practically essential for market access and export capability, particularly in North America.
UL-tested plastics and components minimize risks such as fire, electric shock, or mechanical failure under load.
Certification is based on comprehensive testing of flammability, electrical behavior, heat and aging resistance, mechanical integrity, and chemical resistance.
For manufacturers, an existing UL listing facilitates a seamless certification process for the complete product, as all relevant components and materials can already demonstrate compliance with UL standards.
Plastic compounds with UL Listing therefore provide maximum planning reliability and accelerate project implementation for OEMs and system suppliers.
Long-term heat aging resistance is a key factor for components that must perform reliably over many years in environments with elevated temperatures. The G2 classification (typically 50,000 hours at elevated test temperatures) confirms that the material largely retains its mechanical properties even after prolonged thermal exposure.
Heat aging testing is carried out in standardized hot-air ovens under defined temperature and time conditions:
Material samples are exposed to elevated temperatures for specified periods (e.g., 5,000, 20,000, or 50,000 hours).
Material properties – such as tensile strength, elongation at break, and impact strength – are tested at regular intervals.
The measured values are compared with the initial properties. A successful classification (such as G2, 50,000 hours) confirms that the material does not exhibit critical degradation due to aging within the specified period.
This material qualification is particularly important in safety-critical applications designed for service lives of at least ten years. It significantly reduces the risk of component failure, smoldering, or fire.
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Our Component in Focus
The targeted combination of a glass fiber-reinforced, flame-retardant and heat-stabilized PA6/6.6 blend not only makes battery disconnects safer but also supports weight reduction and cost-efficient processing compared to metallic materials. Excellent flow properties enable the production of precise, thin-walled structures that combine mechanical stability with electrical insulation. This is particularly essential for the reliable protection of electrical systems in the event of a failure.
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Left: Individual components. Right: Assembled component group.
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Detailed View of the Component Assembly
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Our Portfolio of Flame-Retardant Compounds
We help you find the right product from our flame-retardant portfolio:
AKROMID® A / B / C FR: Flame-retardant PA66, PA6, PA66/PA6 blend
AKROMID® T91 FR: Flame-retardant PA9T
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, halogen-containing flame retardants, antimony trioxide, zinc borate, and PFAS-containing anti-dripping agents. Innovative and future-proof!
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The Perfect Compound for Every Application
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Disclaimer: All information provided on this website is based on our current knowledge and experience. No legally binding guarantee of specific properties or suitability for a particular application can be derived from this information. Processors and users are not exempt from conducting their own tests and evaluations for each specific application. AKROMID®, AKROLEN®, AKROLOY®, AKROTEK®, ICX®, PRECITE®, and DIA(hr)LOG® are registered trademarks of AKRO-PLASTIC GmbH.
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