Sound-absorbing melamine foam used for Volkswagen engine covers

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  • Thermoset melamine foam specifically developed for thermoforming
  • Foam withstands temperatures up to 240 °C / 460 ºF
  • Benchmark for small turbocharged engines

Sound-absorbing Basotect TG melamine foam of BASF is now being used for the acoustic layer in the Volkswagen EA888 engine for the Jetta, Golf, Passat, Tiguan, and Beetle models produced in North America. Volkswagen chose Basotect-based acoustic parts provided by the foam converter Rogers Foam of Somerville, MA, that are further assembled by the Tier 1 supplier of the engine cover, Exo-s, of Sherbrooke, Canada.

BASF’s sound-absorbing Basotect® TG melamine foam is now being used for the acoustic layer in the Volkswagen EA888 engine for the Jetta, Golf, Passat, Tiguan, and Beetle models produced in North America (Source: BASF)

BASF’s sound-absorbing Basotect TG melamine foam is now being used for the acoustic layer in the Volkswagen EA888 engine for the Jetta, Golf, Passat, Tiguan, and Beetle models produced in North America (Source: BASF)

Thermoset melamine foam specifically developed for thermoforming

Higher-performing and direct-injection engines are being used in today’s automotive manufacturing. These engines create higher levels of heat and noise that impact the driving comfort. The engine cover developed by Exo-s and Rogers Foam using Basotect TG foam was able to meet VW’s needs. The material is the only thermoset melamine foam, which is specifically manufactured for thermoforming in order to make sophisticated three-dimensional components and customized elements for tight spaces.

Foam withstands temperatures up to 240 °C / 460 ºF

The foam engine cover provides superior noise absorption, flame resistance and weight reduction in the high heat environment of the engine compartment. Because of its open-cell, fine foam structure, the sound absorption values in the medium and high frequency ranges are very good. The use of a non-woven fleece covering the BASF foam helps increase the noise insulation over the whole range of frequencies.

In addition, Basotect makes the engine cover flame-retardant and prevents it from maintaining a flame. These fire resistant properties ensure to meet the UL 94 V-0 fire rating. The BASF foam can withstand temperatures up to 240 °C (460 ºF) while maintaining its NVH properties. With a density of only 9 kg/m3, the material is also much lighter than conventional insulating materials used in under-hood applications, which is highly desirable as it reduces both fuel consumption and CO2 emissions.

Benchmark for small turbocharged engines

The EA888 engine cover is currently being manufactured for use in the VW facilities in Chattanooga, TN and Puebla, Mexico, with future plans to expand the EA888 engine cover line.

Volkswagen’s EA888 four cylinder engine has set the benchmark for small-displacement turbocharged engines. Designed to be lighter and more fuel-efficient, the new EA888 Gen 3 is turbocharged and the direct-injection four-cylinder’s additional low-speed torque has also enhanced the performance of the car.



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