Covestro has introduced their next-generation flame-retardant encapsulation polyurethane foam technology, which tackles battery safety, one of the biggest obstacles to the global deployment of electric vehicles (EVs). Covestro’s standing as a reliable materials partner in the developing EV value chain is strengthened by this invention.
With the launch of the ground-breaking national standard GB 38031-2025: Electric Vehicles Traction Battery Safety Requirements, China, the largest EV market in the world, is making a significant move. This rule, which goes into effect in July 2026, requires batteries to be safe against fire and explosion, even in the case of a thermal runaway. In the upcoming years, it is anticipated that these strict restrictions will influence international safety standards.
- Aligned with China’s new battery safety regulation in the world’s largest EV market
- Polyurethane foam limits thermal propagation to enhance battery safety
- Supports global EV growth through advanced materials innovation
Breakthrough flame-retardant encapsulation foam technology
Covestro’s newly launched Baysafe® BEF flame-retardant encapsulation foam series is designed to minimise 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 Specialities 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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