By ATN
Summary: Covestro has launched its Baysafe® BEF flame-retardant encapsulation foam technology to improve electric vehicle (EV) battery safety and meet stringent upcoming standards, such as China’s GB 38031-2025 regulation. The new polyurethane foam minimizes thermal propagation between cells to prevent fire or explosion during thermal runaway events. Lightweight and effective, the solution supports global EV adoption by addressing critical safety concerns. It also reinforces Covestro’s broader materials portfolio for battery systems, including battery covers and impact-absorbing components, helping OEMs meet rising safety expectations across EV and energy storage applications.
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- Covestro’s new flame-retardant foam inhibits fire spread between EV battery cells, directly addressing thermal runaway containment.
- Launch is timed to align with China’s GB 38031-2025 regulation, likely to influence future global EV battery safety standards.
- Lightweight polyurethane-based solution integrates easily into current battery pack designs, supporting mass-market scalability.
Covestro has unveiled its next-generation flame-retardant encapsulation polyurethane foam technology, addressing one of the most critical challenges in electric vehicle (EV) adoption worldwide: battery safety. This innovation strengthens Covestro’s position as a trusted materials partner in the evolving EV value chain.
As the world’s largest EV market, China is taking a decisive step with the introduction of the groundbreaking national standard GB 38031-2025: Electric Vehicles Traction Battery Safety Requirements. Effective from July 2026, this regulation demands that batteries must not catch fire or explode—even in the event of a thermal runaway. These stringent requirements are expected to shape global safety standards in the years ahead.
Breakthrough flame-retardant encapsulation foam technology
Covestro’s newly launched Baysafe® BEF flame-retardant encapsulation foam series is designed to minimize thermal propagation between battery cells—tackling a key safety concern that has challenged consumer trust in EVs. The lightweight foam delivers superior flame-retardant performance by effectively inhibiting fire spread, significantly enhancing battery safety in applications ranging from EVs to portable energy storage systems.
“This innovation represents a significant step toward enabling sustainable mobility through enhanced safety,” said Akhil Singhania, Global Head of PU Specialties in Covestro’s Tailored Urethanes Business Entity. “By launching our advanced flame-retardant technology, Covestro reaffirms its commitment to innovation and strengthens our product portfolio to meet the evolving needs of the EV industry.”
This development comes at a pivotal time as EV adoption accelerates globally and safety regulations become more demanding. As Chinese automotive companies expand internationally, Covestro’s innovative materials solutions illustrate how technological advancements support successful cross-border market growth.
Comprehensive solutions for the new energy ecosystem
Beyond encapsulation foams, Covestro offers a wide range of polyurethane-based solutions for EV batteries, including battery covers and shock-absorbing materials. The new Baysafe® BEF technology further strengthens Covestro’s position in the fast-growing new energy sector, supporting safer, more reliable electric mobility applications such as new energy vehicles and e-bikes, as well as portable battery generators.
With continued innovation in materials science, Covestro is supporting the development of next-generation electric transportation by providing a reliable technological foundation that meets evolving safety and performance requirements.
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