Huntsman unveils POLYRESYST EV5005, a new intumescent polyurethane coating offering passive fire protection for EVs, set to debut at The Battery Show Europe.
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| Huntsman launches POLYRESYST EV5005, a spray-applied intumescent coating offering advanced fire protection and mechanical strength for EV components. Image: Huntsman |
TIENEN, BELGIUM — May 30, 2025:
Huntsman, a global leader in polyurethane-based technology, has unveiled a new intumescent polyurethane coating system designed to improve fire protection in electric vehicles (EVs). Named POLYRESYST EV5005, the innovation provides passive fire protection for metal and composite surfaces within EVs, enhancing structural integrity without sacrificing manufacturing flexibility. The product will be showcased at The Battery Show Europe in Stuttgart, Germany, from June 3 to 5, 2025.
The launch aligns with growing demand for safer EV technologies, particularly as automakers face regulatory pressure and heightened public scrutiny over battery fire risks. Huntsman’s new coating solution addresses these concerns by offering thermal event protection that can be applied without thickness limitations. It delivers a fast-curing, high-strength layer with abrasion resistance and hydrolytic stability—qualities essential to preserving vehicle safety in the event of battery impact or thermal runaway.
Speaking about the innovation, Irina Bolshakova, Global Automotive Marketing Director at Huntsman, said: “The use of technologies that delay or prevent thermal runaway is now a major priority in the automotive sector. Our POLYRESYST EV5005 system meets that need by combining high performance with efficient processing on automated production lines.”
Designed for speed and efficiency, the system adheres to a wide range of substrates and sets in seconds, eliminating the need for ovens or post-curing. With short tack-free times, manufacturers can apply multiple coats rapidly and move coated components with minimal delay, reducing production time and costs.
POLYRESYST EV5005 is part of a broader portfolio of polyurethane-based EV solutions that Huntsman will promote at The Battery Show Europe. These include the SHOKLESS battery encapsulation foams for thermal insulation and vibration damping, VITROX systems for lightweight battery casing with high thermal resistance, and RIMLINE FC, a moldable foam core for composite enclosures and structural components.
To highlight these advancements, Josh Wimble, Huntsman’s Market Segment Manager for EV Batteries, will present at the Battery Tech Theater on June 3 at 10:00 a.m. His session, titled “Enabling Next-Gen EV Batteries with Huntsman Material Innovations,” will delve into the company’s comprehensive solutions for battery safety and performance.
Huntsman Corporation, headquartered in the United States, is a publicly traded multinational chemical manufacturer with 2024 revenues of approximately $6 billion. With over 60 production, R&D, and operational facilities across 25 countries, the company employs around 6,300 people and serves a broad spectrum of industrial and consumer markets. Through continued innovation like POLYRESYST EV5005, Huntsman reinforces its commitment to shaping the future of safe, sustainable electric mobility.