The newly introduced coatings, Alesta® e-PRO FG Black and Alesta® e-PRO Dielectric Gray, have been developed to offer superior heat protection and electrical insulation for EV battery applications.
Axalta Coating Systems, a global supplier of coatings, has unveiled two new products aimed at improving safety and performance in electric vehicle (EV) battery systems: Alesta® e-PRO FG Black and Alesta® e-PRO Dielectric Gray. The launch, announced at The Battery Show North America, highlights the company’s ongoing commitment to innovation within the automotive and energy storage sectors.
“While electric vehicles are statistically far less likely to catch fire than gasoline-powered vehicles, high-profile incidents and misinformation continue to impact public perception. These breakthrough products demonstrate the amazing power of coatings to rise to new challenges and reflect Axalta's proven history of innovating products that impact the world for the better,” has stated Robert Roop, Senior Vice-President and Chief Technology Officer at Axalta.
Despite growing adoption of electric vehicles, consumer concerns remain regarding battery safety. Thermal runaway in EV batteries, though rare, poses a serious risk that can result in fires, explosions, and structural damage. If one battery cell overheats, it may trigger a chain reaction, releasing extreme heat, flames, and smoke at temperatures exceeding 1200°C. When integrated into a validated OEM battery system, Axalta’s new coatings could enhance thermal stability and electrical insulation performance.
Alesta® e-PRO FG Black is a premium powder coating engineered for thermal stability and secondary fire protection in EV battery systems. The coating is designed to withstand ignition, expansion, and smoke generation at temperatures of up to 1200°C, helping to slow the spread of fire during thermal events.
Key features include:
- Maintains thermal integrity under direct flame and extreme heat (600–1200°C).
- Zero smoke emission at high temperatures.
- Strong corrosion protection, either standalone or as an enhancement over electrocoated substrates.
Alesta® e-PRO Dielectric Gray is an epoxy-based powder coating
providing high-performance electrical insulation in high-voltage environments, including EV battery packs and stationary energy storage systems. It delivers excellent hipot test results, improving system reliability.
Key features include:
- Industry-leading edge coverage for consistent electrical insulation and high hipot pass rates.
- High flexibility to accommodate complex geometries with reduced risk of cracking.
- Superior lap shear strength for enhanced structural integrity under stress.
- Passes 6KV hipot for dielectric performance.
Both coatings have undergone rigorous testing to ensure electrical insulation and thermal protection. Dielectric Gray has been tested to UL 94 V0 and IEC 60243-1 standards, among others. FG Black has been subjected to direct flame exposure, single-cell thermal runaway, and UL 2596 TaG tests, demonstrating no smoke emission or ignition even at 1200°C.
“Our customers are looking for technologies that can withstand extreme environments and support their efforts to build safe and reliable battery systems. These new coatings reflect our commitment to innovation and to partnering with customers to meet the challenges of next-generation mobility," has added Roop.
The coatings are aimed at global automotive manufacturers producing EVs, as the worldwide EV market is projected to surpass 20 million units in 2025, representing over a quarter of all cars sold globally. Leading OEMs and Tier 1 suppliers are currently conducting additional testing in line with their design specifications and pre-production approval processes.