Huntsman Unveils Polyurethane Fire Protection Coating for EVs

Huntsman has introduced a new intumescent polyurethane coating system, POLYRESYST® EV5005, designed to improve fire safety in electric vehicles (EVs). This advanced coating offers passive fire protection for both metal and composite parts without limiting design flexibility. It helps safeguard the structural integrity of battery cells, tackling a key concern in modern EV development.

The launch comes at a time when the automotive industry is increasingly focused on fire safety, influenced by regulatory changes, evolving technology and growing consumer awareness. Huntsman will present POLYRESYST® EV5005 at The Battery Show Europe in June, along with its broader polyurethane systems portfolio for EV makers.

“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,” said Irina Bolshakova, Global Automotive Marketing Director at Huntsman.

POLYRESYST® EV5005 is designed for easy spray application without thickness limits, allowing manufacturers to meet strict fire standards. It cures quickly, provides strong mechanical performance, resists moisture and abrasion, and creates a protective yet flexible coating that reinforces key components during impact or heat exposure. Developed for automated production lines, it adheres to various surfaces and cures without the need for an oven. Its short tack-free time also allows for fast re-coating and efficient production flow.

This new intumescent polyurethane solution adds to Huntsman's existing lineup, including SHOKLESS™ systems for battery encapsulation and VITROX® technologies for lightweight battery covers.

Source: Huntsman Corporation