Covestro unveils flame-retardant foam for EV batteries, enhancing safety and aligning with China's upcoming stringent battery safety regulations.
Covestro, a leading innovator in materials science, has launched a new flame-retardant encapsulation polyurethane foam technology aimed at addressing one of the most pressing concerns in the electric vehicle (EV) sector: battery safety. With EV adoption growing rapidly around the world, the safety of lithium-ion batteries—especially their vulnerability to thermal runaway events—remains a critical issue that hinders consumer confidence. Covestro’s latest solution is designed to significantly reduce such risks, enhancing the safety and reliability of EV batteries.
The company’s new innovation, marketed under the Baysafe® BEF series, offers advanced flame-retardant capabilities tailored for battery modules. This lightweight foam helps contain and minimize the spread of heat and fire between individual battery cells, thereby mitigating the risk of thermal propagation—a key safety hazard in high-density battery packs used in EVs and other energy storage applications. It is particularly suited for applications including electric vehicles, portable battery generators, and other mobile energy storage systems.
Akhil Singhania, Global Head of PU Specialties in Covestro’s Tailored Urethanes Business Entity, emphasized the strategic significance of this development, stating, “This innovation marks an important milestone in advancing sustainable mobility through increased battery safety. Our latest flame-retardant technology showcases our ongoing commitment to innovation and strengthens Covestro’s product offerings to meet the evolving demands of the EV industry.”
This launch coincides with a significant regulatory development in the world’s largest EV market—China. The country has introduced a stringent new safety regulation, GB 38031-2025, which outlines traction battery safety requirements for electric vehicles. Slated to take effect in July 2026, the standard mandates that EV batteries must not ignite or explode even in extreme thermal events. This regulation is expected to set a global benchmark for EV safety and accelerate the push for higher safety standards across international markets.
Covestro’s Baysafe® BEF foam arrives at a crucial time as Chinese EV manufacturers are expanding their reach into international markets. The adoption of advanced materials like Covestro’s flame-retardant foam will be essential for compliance with both domestic and global safety regulations. It also reinforces the company's position as a key enabler in the broader EV ecosystem.
In addition to encapsulation foam, Covestro provides an array of polyurethane-based materials designed for electric mobility, including shock-absorbing components and battery enclosures. The introduction of the new foam technology strengthens its comprehensive product portfolio tailored for new energy vehicles, e-bikes, and other electric mobility applications.
By continuing to innovate in high-performance, safety-centric materials, Covestro is playing a pivotal role in supporting the global transition to cleaner, safer electric transportation.
