Flame-retardant foam boosts electric vehicle battery safety

Covestro’s lightweight foam minimizes thermal propagation between battery cells, inhibiting fire spread.

Rendering of a battery with fire protective foam inside
Baysafe BEF (blue foam) is specially developed to enhance battery safety in electric vehicles by helping limit thermal propagation between cylindrical cells.
CREDIT: COVESTRO

Covestro has unveiled its next-generation flame-retardant encapsulation polyurethane foam technology, addressing one of the most critical challenges in electric vehicle (EV) adoption worldwide: battery safety. The company's newly launched Baysafe BEF flame-retardant encapsulation foam series is designed to minimize thermal propagation between battery cells, tackling a key safety concern that has challenged consumer trust in EVs.

The lightweight foam delivers flame-retardant performance by effectively inhibiting fire spread, significantly enhancing battery safety in applications ranging from EVs to portable energy storage systems.

“This innovation represents a significant step toward enabling sustainable mobility through enhanced safety,” says 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.”