Axalta Introduces Alesta e-Pro Coatings for EV Thermal Runaway Mitigation
Alesta e-Pro FG Black and Alesta e-Pro Dielectric Gray powder coatings offer extreme heat protection and high electrical insulation for global EV battery manufacturers.
Source | Axalta Coating Systems
Alesta e-Pro FG Black and Alesta e-Pro Dielectric Gray, recently introduced products by Axalta Coating Systems Ltd. (Glen Mills, Pennsylvania) as part of the company’s broad portfolio of battery coatings, are engineered for extreme heat protection and better electrical insulation in electric vehicle (EV) battery applications.
Thermal runaway in EV batteries remains a rare yet serious risk that can lead to fires, explosions and structural failure. When applied as part of a validated OEM battery system, Axalta says that these coatings are designed to contribute to improved thermal stability and electrical insulation performance.
Alesta e-Pro FG Black is a powder coating engineered for thermal stability and secondary fire protection. This advanced coating is designed to resist ignition, expansion and smoke generation at extreme temperatures up to 1200°C, helping to delay fire propagation from thermal events. Thermal integrity is maintained under direct flame and extreme heat (600-1200°C), there are zero smoke emission at high temperatures and the coating offers strong corrosion protection for standalone or enhanced protection over electrocoated substrates.
Alesta e-Pro Dielectric Gray is an epoxy-based powder coating designed to provide robust electrical insulation in high-voltage environments such as EV battery packs and stationary energy storage systems. This coating provides optimal hipot test yield, improving reliability. Key design features include edge coverage, ensuring consistent electrical insulation and high hipot pass rates; high flexibility accommodating complex geometries with reduced risk of cracking; and high lap shear strength for enhanced structural integrity under applied stress. This coating also passes 6-kV hipot for dielectric performance.
Alesta e-Pro products have undergone rigorous testing for electrical insulation and thermal protection. The Dielectric Gray has been tested for UL 94 V0 and IEC 60243-1 among several others. The FG Black product has been tested for direct flame exposure, single-cell thermal runaway and UL 2596 TaG tests. When exposed to direct flame at 1200°C, Axalta’s Alesta e-Pro FG Black produces no smoke and does not catch fire during thermal events.
The coatings are designed for global automotive manufacturers producing EVs. Several leading OEMs and Tier 1 suppliers are currently conducting additional testing based on their specific designs and pre-production part approval processes.
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