Covestro unveiled its next-generation flame-retardant encapsulation polyurethane foam technology – Baysafe BEF flame-retardant encapsulation foam series – addressing the critical battery safety challenge in electric vehicle (EV) adoption.

Battery demonstrator made from Baysafe BEF (blue foam), optionally combined with Baysafe EA as a crash absorber (beige foam).

China sets stringent requirements for EV battery safety

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

The newly launched Baysafe BEF flame-retardant encapsulation foam series is designed to minimize thermal propagation between battery cells, tackling a key safety concern 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.

Comprehensive solutions for new energy market

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.