Axalta has introduced two new powder coatings—Alesta e-PRO FG Black and Alesta e-PRO Dielectric Gray—developed to address heat management and insulation requirements in EV battery applications.

Alesta e-PRO FG Black is designed for thermal stability and secondary fire protection in EV battery systems. According to Axalta, this coating resists ignition, expansion, and smoke generation even during thermal events at temperatures up to 1200°C. Technical features include the maintenance of thermal integrity under direct flame and extreme heat (600–1200°C), zero smoke emission at high temperatures, and robust corrosion protection either standalone or over electrocoated substrates.

Alesta e-PRO Dielectric Gray is an epoxy-based powder coating selected for its electrical insulation properties in high-voltage settings such as EV battery packs and stationary energy storage. It provides strong edge coverage for electrical insulation, high yield in high potential (hipot) testing, flexibility for complex geometries, and passes 6 kV hipot criteria. The company says this product also demonstrates superior lap shear strength for structural reliability under applied stress.

The Dielectric Gray coating has been evaluated for UL 94 V0 and IEC 60243-1 standards, while FG Black has demonstrated performance under direct flame exposure, single-cell thermal runaway and UL 2596 TaG tests. During direct flame exposure at 1200°C, the FG Black coating produced no smoke and did not ignite, according to the company.

“Our customers are looking for technologies that can withstand extreme environments and support their efforts to build safe and reliable battery systems,” said Dr. Robert Roop, Senior Vice President and Chief Technology Officer at Axalta. “These new coatings reflect our commitment to innovation and to partnering with customers to meet the challenges of next-generation mobility.”

Several leading original equipment manufacturers and Tier 1 suppliers are currently conducting additional validation tests based on their design and pre-production approval processes.

Source: Axalta