German materials giant Covestro has launched its latest Baysafe BEF flame‑retardant encapsulation polyurethane foam, designed to significantly enhance fire safety for electric vehicle (EV) battery packs. The innovation addresses a critical concern in the EV market—battery thermal runaway and fire risks.
The breakthrough follows the introduction of China’s GB 38031‑2025 battery safety standard, effective July 2026, which mandates that batteries must resist fire and explosion even during thermal events. As the world’s leading EV market, China’s regulatory shift will likely influence global safety norms. Covestro’s foam technology is positioned to meet these heightened requirements.
Covestro’s lightweight Baysafe BEF foam suppresses thermal propagation between cells, effectively containing potential fire escalation within battery modules. Its polyurethane structure also provides a mechanical barrier, offering protection across applications—from passenger EVs to portable energy systems.
Akhil Singhania, global lead of PU Specialties at Covestro’s Tailored Urethanes division, described the foam as “a significant step toward enabling sustainable mobility through enhanced safety,” reinforcing Covestro’s commitment to innovation and its leadership in advanced EV materials.
Covestro’s materials portfolio extends beyond foam to include flame‑retardant Bayblend polycarbonate/ABS blends for cell holders and Makroblend resins for battery housings. The Baysafe BEF series complements these, supporting modern cell‑to‑pack battery architectures with strong adhesion and torsional stiffness.
As EV adoption accelerates worldwide and safety standards tighten, Covestro’s new foam solution strengthens its position in the materials supply chain. It supports safer, more reliable electric mobility—including e‑bikes, battery generators and EVs—and ensures OEMs and battery producers can meet evolving demands.
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