Huntsman’s POLYRESYST® EV5005 system is a fast-curing, spray-applied polyurethane solution, offering robust mechanical strength, hydrolytic stability, and abrasion resistance.
Huntsman
has introduced the new intumescent polyurethane coating system POLYRESYST® EV5005, developed specifically for automotive applications, which provides passive fire protection to metal and composite substrates used in electric vehicles (EVs) – without compromising design flexibility. The new solution has been unveiled at The Battery Show Europe 2025.
The launch aligns with growing demand from EV manufacturers for enhanced fire safety measures, driven by regulatory developments, technological advances and increased consumer awareness. The new system forms part of Huntsman’s broader range of polyurethane technologies for electric vehicles. Additional technologies featured at the Stuttgart event include SHOKLESS™ battery encapsulation foam systems and VITROX® WCM and RTM systems, designed to create lightweight battery casing covers.
“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,” has stated Irina Bolshakova, Global Automotive Marketing Director at Huntsman.
Designed for use in automated production environments, the system adheres well to a variety of substrates, sets in seconds without the need for ovens or post-curing, and allows rapid layering due to a short tack-free time. This efficiency enables manufacturers to save time and reduce production costs.
The new coating complements Huntsman’s other polyurethane-based solutions for EV battery systems, including:
- SHOKLESS™ polyurethane systems – lightweight, low- to high-density foam systems offering encapsulation with thermal insulation and vibration damping. Available for common polyurethane dispensing processes or as prefabricated components, SHOKLESS™ solutions offer broad processing flexibility.
- VITROX® technologies – a suite of polyurethane systems engineered for lightweight battery casing covers with strong thermal resistance and barrier properties, contributing to protection against thermal runaway.
- RIMLINE® FC system – a mouldable, tunable foam core solution used in composite sandwich structures. Endorsed by a leading global OEM, this technology supports applications such as battery enclosures, underfloor structures, door frames, semi-structural parts, and acoustically optimised components.