Huntsman launches passive fire protection system for electric vehicle battery components
Iain Hoey
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Huntsman unveils polyurethane coating for passive fire protection in EVs
Huntsman has announced the launch of a new intumescent polyurethane coating system designed to enhance passive fire protection in electric vehicles.
According to Huntsman, the POLYRESYST EV5005 coating can be applied to both metal and composite substrates used in EV battery enclosures, helping to preserve structural integrity in the event of a fire or thermal incident.
The system was developed in response to increasing safety expectations from regulators and consumers in the EV sector, the company said.
Huntsman confirmed the new coating was showcased at The Battery Show Europe, which took place in Stuttgart in early June 2025, alongside other polyurethane systems it has developed for EV battery applications.
The company added that the new formulation does not restrict vehicle design or production processes and has been engineered for compatibility with automated spray application.
Product aims to improve fire performance and production speed
Huntsman stated that the POLYRESYST EV5005 polyurethane coating was created to help EV manufacturers meet fire safety standards while maintaining production efficiency.
The material is designed to be applied without minimum or maximum thickness limitations, enabling customisable fire protection coverage across battery enclosures.
It is fast curing, according to the company, with abrasion resistance and hydrolytic stability, and delivers a flexible but strong layer.
The system is also formulated for high-throughput automated production lines.
Huntsman said it adheres to a wide range of substrates and sets within seconds, eliminating the need for post-curing or ovens.
A short tack-free time allows multiple coats to be applied rapidly, helping speed up workflows and reduce bottlenecks.
System supports structural protection in thermal events
Huntsman highlighted that one of the main benefits of the POLYRESYST EV5005 system is its contribution to structural integrity in the event of a thermal runaway or mechanical impact.
The coating is intended for use within EV battery modules and packs, which are at heightened risk of ignition due to concentrated energy storage.
Irina Bolshakova, Global Automotive Marketing Director at Huntsman, said: “The use of technologies that can help delay or prevent thermal runaway is a hot topic in the automotive industry.
“Manufacturers are actively looking for materials that enable them to integrate additional fire resistance into battery enclosures and other interior components, without adding weight or complexity to the design and manufacture of vehicles.
“POLYRESYST EV5005 system has been developed with exactly those needs in mind and is part of a wider portfolio of products that we offer to help safeguard the structural integrity of EV batteries.”
Complementary solutions presented at trade event
Huntsman noted that its wider EV materials portfolio was also promoted at The Battery Show Europe.
This included SHOKLESS polyurethane foam systems, designed to protect battery modules and packs through thermal insulation and vibration damping.
The company said SHOKLESS materials are compatible with standard polyurethane processes and can be prefabricated.
Also exhibited were Huntsman’s VITROX WCM and RTM technologies, which support the production of thermally resistant lightweight upper battery covers.
According to Huntsman, the range is aimed at reducing weight while maintaining resistance to thermal propagation.
RIMLINE FC polyurethane systems were also presented.
These are designed for composite sandwich structures in EVs and can be used in underfloor elements, door inserts and other semi-structural parts.
Huntsman presentation highlighted battery material innovations
Huntsman confirmed that its automotive team participated in the conference programme at The Battery Show Europe.
Josh Wimble, Market Segment Manager for EV Batteries at Huntsman, delivered a presentation titled Enabling Next-Gen EV Batteries with Huntsman Material Innovations.
The session took place on 3 June 2025 at the Battery Tech Theater and outlined the company’s approach to EV battery material development.
Wimble described the various polyurethane systems Huntsman has introduced to support safer, more efficient EV battery manufacturing.
The presentation formed part of the company’s broader engagement at the event, where it also met with manufacturers and suppliers to discuss technical requirements and product integration.
Huntsman launches passive fire protection system for electric vehicle battery components: Summary
Huntsman has launched a new intumescent polyurethane coating system called POLYRESYST EV5005.
The coating is designed to provide passive fire protection for EV battery enclosures.
The company said it is suitable for metal and composite substrates and can be applied without thickness restrictions.
It cures quickly and adheres to various surfaces without the need for ovens or post-curing.
The system was developed for use in automated production environments.
Huntsman showcased the product at The Battery Show Europe in Stuttgart in June 2025.
Other technologies presented included SHOKLESS foams and VITROX polyurethane casing systems.
RIMLINE FC systems were also featured for use in lightweight composite EV parts.
Irina Bolshakova, Huntsman’s Global Automotive Marketing Director, said the product addresses current fire safety demands in EV manufacturing.
Josh Wimble, Market Segment Manager, presented details of Huntsman’s EV battery portfolio at the event on 3 June.