Covestro Launches Flame-Retardant Encapsulation Foam for Electric Vehicle Batteries

Covestro's new flame-retardant encapsulation polyurethane foam technology strengthens the company's position as a reliable materials partner in the evolving electric vehicle supply chain.

Covestro has introduced a new generation of flame-retardant encapsulation polyurethane foam technology to address battery safety, one of the most critical challenges in global electric vehicle (EV) adoption. This innovation further reinforces Covestro's position as a dependable materials partner in the developing EV supply chain.

China, the world's largest EV market, is taking a decisive step with the introduction of the groundbreaking national standard GB 38031-2025: Electric Vehicles Traction Battery Safety Requirements. Taking effect from July 2026, this new regulation requires batteries to be designed so they do not ignite or explode even in thermal runaway situations. These requirements are expected to shape global safety standards in the coming years.

Groundbreaking 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 — addressing a critical safety concern that has shaken consumer confidence in EVs. This lightweight foam delivers superior flame-retardant performance by effectively preventing fire spread, significantly enhancing battery safety across diverse applications ranging from electric vehicles to portable energy storage systems.

Akhil Singhania, Global Head of Polyurethane Special Products, Covestro Tailored Urethanes Business Unit, stated, "This innovation represents an important step toward enabling sustainable mobility through enhanced safety. By bringing our advanced flame-retardant technology to market, Covestro once again demonstrates its commitment to innovation and strengthens our product portfolio to meet the evolving needs of the EV sector."

This development comes at a critical time when electric vehicles are being rapidly adopted globally and safety regulations are becoming increasingly demanding. As Chinese automotive companies expand internationally, Covestro's innovative material solutions demonstrate how technological advances support successful cross-border market growth.

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