17. Jul 2025
New advanced flame-retardant encapsulation foam for EV batteries
Covestro (Leverkusen, germany) 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 launchedBaysafe® 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.