Covestro Launches Fire-Safe Foam for EV Battery Protection

Covestro, the German materials powerhouse, has launched its Baysafe BEF flame‑retardant encapsulation polyurethane foam – a breakthrough aimed at preventing thermal propagation between battery cells in electric vehicles (EVs) and portable energy storage systems.

This debut aligns precisely with China’s upcoming GB 38031‑2025 “Electric Vehicles Traction Battery Safety Requirements” standard, set to take effect on July 1, 2026. For the first time, the regulation mandates that EV batteries must not catch fire or explode, even during thermal runaway events, and any resulting smoke must remain outside the passenger cabin.

Covestro’s Baysafe BEF series is lightweight yet boasts strong flame‑retardant performance, specially formulated to limit thermal propagation – a leading cause of EV battery fires. According to Akhil Singhania, Global Head of PU Specialties at Covestro, “This innovation represents a significant step toward enabling sustainable mobility through enhanced safety”.

Besides foam, Covestro supports the EV ecosystem with additional polyurethane solutions, including battery covers, shock‑absorbers, and flame‑retardant Bayblend PC/ABS blends and Makroblend resins.

This strategic launch comes amid a wave of high-profile mandates: new crash-impact and fast-charging tests are introduced under GB 38031‑2025, pushing battery compliance and consumer trust to unprecedented levels.

In conclusion, Covestro is leveraging its position in materials science to help EV manufacturers meet—and exceed—the world’s most stringent battery-safety benchmarks, reinforcing its role as a vital partner in safer e-mobility growth.