Redefining Electrical Connectors: The Rise of Engineering Plastics

Why Connector Material Choice Matters More Than Ever

In today's high-tech world, electrical connectors are everywhere—from electric vehicles and solar panels to industrial automation systems. These small components are responsible for reliably transferring power and signals under demanding conditions. But not all connector materials are created equal.

Historically, many manufacturers relied on metals like brass or beryllium copper. While strong and conductive, these materials come with trade-offs: they are prone to corrosion, require complex manufacturing processes, and increase product weight. With modern applications demanding better performance, safety, and sustainability, the industry is shifting toward high-performance engineering plastics—and for good reason.

The Rise of Advanced Engineering Plastics for Connectors

Engineering resins like LEONA™ SN Series and XYRON™ 644Z, developed by Asahi Kasei, are reshaping the landscape of electrical connector design. These materials outperform traditional options across nearly every metric:

• Flame retardancy: Both LEONA™ SN and XYRON™ 644Z meet or exceed UL94 V-0 standards without relying on halogens or red phosphorus.
• Weather and chemical resistance: Excellent durability against moisture, UV exposure, and harsh chemicals ensures performance in tough environments.
• Electrical insulation: High CTI and low dielectric loss help protect sensitive electronics from failure.
• Sustainability: These halogen-free, recyclable materials contribute to greener, safer product designs.

LEONA™ SN Series: Built for High-Voltage, High-Safety Applications

Asahi Kasei’s LEONA™ SN Series is a next-generation PA66+6I resin tailored for high-voltage applications. What makes it a standout?

• Achieves UL94 V-0 flame retardancy at 0.75 mm—without halogens or red phosphorus.
• Offers CTI of 600V and GWIT of 750°C, providing exceptional electrical safety.
• Performs under moisture and chemical exposure, ensuring long-term mechanical integrity.
• Optimized for laser welding and marking, making it ideal for mass production environments.

Use cases include:

• EV battery connectors, where safety and flame resistance are critical.
• Bus bar covers, which require strong electrical insulation.
• Rail applications, where it meets EN 45545-2 HL3 standards for fire safety.

XYRON™ 644Z: The High-Performance mPPE for Next-Gen Connectors

XYRON™ 644Z is a modified polyphenylene ether (mPPE) resin that provides a unique balance of performance and processability. It's designed for high-voltage connector applications where lightweight, flame retardant, and UV-resistant materials are needed.

Key benefits:

• Inherent flame retardancy, rated UL94 V-0 and 5VA without additional additives.
• Maintains dimensional stability even in humid conditions.
• Excels in solar power and EV battery storage applications where long-term reliability is crucial.
• Recyclable and lightweight, supporting sustainability goals and reducing carbon footprint.

More Than Just Performance: A Sustainable Choice

Connector manufacturers are under increasing pressure to improve not just product performance, but also environmental impact. Both LEONA™ SN Series and XYRON™ 644Z are free from halogens and red phosphorus, helping reduce toxic emissions and comply with global environmental regulations.

These materials also:

• Lower the carbon footprint due to more energy-efficient processing.
• Reduce waste by extending product life and minimizing failures.
• Support closed-loop manufacturing through recyclability.

Ready to Upgrade Your Connector Materials?

The future of electrical connectors lies in smarter materials—ones that combine safety, efficiency, and sustainability. LEONA™ SN Series and XYRON™ 644Z deliver across the board, making them ideal choices for automotive, solar, industrial, and high-voltage electrical systems.

Interested in testing these materials for your next project?

Contact our experts today to request free samples and get technical support tailored to your application.

If you're looking for expert guidance on selecting durable, high-performance materials for connectors, our team is available to help.    Contact us today to learn more about how our engineered plastics can power your next project.