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Huntsman launches passive fire protection system for electric vehicle battery components
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.
Fire risks in EVs: battery materials, fire protection and regulatory insights
Research examines causes of fire risks in EVs
IDTechEx has reported on the materials and strategies being used to reduce fire risks in electric vehicles, with thermal runaway, battery chemistry and regulation identified as key areas of concern.
The research includes data from multiple reports, such as Fire Protection Materials for EV Batteries 2025–2035: Markets, Trends, and Forecasts, and was presented by IDTechEx experts at the Plastics in Electric & Autonomous Vehicles Conference 2025 – SPE Automotive Division.
The company said that various types of failures in EV battery systems, including wiring faults and defects in specific cells, have previously led to vehicle recalls.
According to IDTechEx, these incidents, along with the financial implications for manufacturers, are contributing to demand for more effective fire protection materials.
The organisation stated that thermal runaway can occur not only when driving, but also during charging, in the event of a crash or while the vehicle is parked.
Material technologies being used to mitigate thermal hazards
IDTechEx reported that aerogels are increasingly used to limit heat transfer between battery cells due to their low thermal conductivity and density.
Other materials identified by the organisation as beneficial for thermal protection include foams, ceramics and mica.
Mica, according to IDTechEx, is easier to apply than aerogels or ceramics and can be installed in low-cost sheets that still offer electrical insulation benefits.
The organisation added that while density is higher for mica-based materials, their practicality and affordability make them widely adopted in various battery designs.
Battery chemistries impact EV fire safety
IDTechEx stated that solid-state batteries can improve safety by replacing flammable liquid electrolytes with thermally stable alternatives.
The company explained that this results in better thermal dissipation, fewer hot spots and reduced heat generation in the event of external heating failures.
IDTechEx added that sodium-ion batteries can be stored at 0V, have lower heat release rates than lithium-ion cells and have shown no flames or ignition during nail penetration testing.
The organisation said that lithium-ion batteries using solid-state electrolytes could potentially match the safety of sodium-ion technologies.
Global regulations lag behind safety innovation
IDTechEx reported that while China has a five-minute early warning requirement for thermal runaway events in EVs, this will be increased to a two-hour delay before visible fire or explosion from July 2026.
The company said that no other global regulations currently impose such time-based requirements at the battery pack level.
IDTechEx expects other regions to introduce similar rules eventually, but noted that implementation is likely to be slower and less strict.
It added that some industries, such as aerospace, apply stricter standards for battery safety than those currently seen in the automotive sector.
Fire risks in EVs: battery materials, fire protection and regulatory insights: Summary
IDTechEx has published findings on the use of materials to mitigate fire risks in electric vehicles.
The research identifies thermal runaway as a persistent hazard during driving, charging, collisions and stationary periods.
IDTechEx reported that battery recalls and financial costs have increased focus on improving safety materials.
Aerogels, foams, ceramics and mica are among the thermal protection materials examined in the report.
Mica is noted for its cost-effectiveness and electrical insulation properties.
Solid-state batteries are identified by IDTechEx as offering improved thermal stability.
Sodium-ion batteries can be transported at 0V and may not ignite during penetration incidents.
China requires a five-minute thermal runaway warning and will raise this to two hours in 2026.
IDTechEx states that no other regions currently have similar mandates.
The organisation predicts global regulations will eventually become stricter.
New fire safety rules for EV chargers create installation challenges in Queensland
New fire safety regulations for EV chargers
New fire safety regulations in Queensland and New South Wales are posing challenges for property developers as they make it difficult to install electric vehicle (EV) chargers in apartment buildings.
As reported by The Driven, these rules require significant fire protection measures, such as sprinklers and smoke management systems, for car parks housing electric cars.
The new guidelines, issued by Fire and Rescue NSW in late April, classify electric cars as “special hazards” and recommend additional requirements, including keeping vehicles and chargers outside buildings and installing advanced fire sprinkler systems and smoke detection alarms.
Fire and Rescue NSW Commissioner Jeremy Fewtrell clarified that these measures are not required for typical home garages but for buildings with underground car parks.
Conflicting guidance on EV chargers
The new guidelines seem to contradict the National Construction Code, prompting experts to call for urgent clarification to avoid high costs and long-term consequences.
Queensland Fire and Emergency Services issued similar advice, including the provision of air-handling systems.
Gary Rake, CEO of the Australian Building Codes Board, stated: “The presence of electric vehicles in a car park is now common enough to be reasonably ‘expected’ and ‘usual’ and therefore not the original intent of the special hazards provisions when they were written.”
He noted that the conditions should only apply if there is an unusual combination of electric cars and specific building features.
Impact on property developers
The changing rules are affecting property developers, architects, designers, and engineers working on new apartment buildings.
A residential developer mentioned that electric vehicle chargers are being removed from some plans due to confusing guidance and increasing demands.
“It would add a significant amount of cost because those car spaces would suddenly need to have a whole lot more infrastructure than they would otherwise have had,” the developer said.
Fred Tuckwell, chairman of the Owners Corporation Network, highlighted that more apartment residents are requesting EV chargers in their car parks but are frustrated by the lack of clear regulations.
He stated: “These rules are making it almost impossible. If we have to comply with the NSW Fire and Rescue rules, this will blow EV charging in private buildings out of the window because of the massive expense.”
Fire safety concerns and statistics
The agency responsible for collecting data on electric vehicle fires in Australia, EV FireSafe, has verified only six EV fires to date, none of which were related to battery charging or spontaneous explosions.
Emma Sutcliffe, CEO of EV FireSafe, mentioned that the greatest fire risk to electric cars follows damage to their batteries.
She noted: “The four leading causes of EV fires are road traffic collisions, submersion in floodwaters, vehicles on recall and vehicles exposed to another fire.”
Tuckwell added: “Why is it that people are asking for EVs to be treated as a special hazard when petrol and diesel vehicles are 10 to 20 times more likely to catch fire?
“To impose huge financial penalties and difficulties, including forcing people to park their car outside, is counter to common sense and to what the real situation is in the real world.”