Covestro Introduces Flame-Retardant Encapsulation Foam For Electric Vehicle Batteries

Covestro has introduced its next-generation flame-retardant encapsulation polyurethane foam technology, which addresses the  most challenging obstacles of the adoption of electric vehicles (EVs): battery safety.

As the world’s largest EV market, China is taking a major 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

 Baysafe® BEF flame-retardant encapsulation foam series is intended to mitigate thermal propagation between battery cells, thereby addressing a safety concern that has undermined consumer confidence in electric vehicles. The lightweight foam provides exceptional flame-retardant performance by effectively preventing the spread of fire, thereby improving battery safety in a variety of applications, including portable energy storage systems and electric vehicles.

“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. 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.