Published
by Rogers Corporation
Elastomeric Material Solutions
When safety is on the line, engineers often look for materials that meet stringent flame standards such as UL 94 V-0. The challenge is that not every foam can deliver. Many polyurethane foams in the market fall short of V-0 performance, or only achieve it in thicker, firmer grades that limit their use in modern compact designs. Silicone foams remain a trusted option, but in applications where extreme temperature or water sealing aren’t required, they can add unnecessary cost.
PORON® 40V0 foam was developed to bridge this gap. The material combines UL 94 V-0 compliance, softness, conformability, siloxane-free and halogen-free chemistry, and long-term reliability—providing engineers with a dependable and cost-effective solution for a wide range of designs.
To understand the development behind PORON 40V0 polyurethane foam, we spoke with Justin Chretien, Senior Product Manager, Global Polyurethanes at Rogers, about why the material was created, what challenges it addresses, and how engineers can put it to work.
We developed this material in response to customer feedback. Engineers across industries have been asking for higher flame-rated materials, but they also wanted a more economical solution than what is typically available today. PORON 40V0 foam was designed to fill that need: it provides the UL 94 V-0 compliance they require, along with softness, excellent compression set resistance, and reliable long-term performance.
Not quite. Many silicones are still the best solution when you need extreme high-temperature resistance, best-in-class water sealing, or extreme chemical resistance. But there are many applications where the primary requirement is simply a V-0 flame rating. In those cases, PORON 40V0 foam gives engineers a more cost-effective option without over-specifying materials.
Many of the existing V-0 polyurethanes are firm and only offered in thicker formats. That makes them less suitable in designs that require softer, more conformable materials. PORON 40V0 foam stands out because it combines softness, compressibility, and V-0 performance in thinner thicknesses, which opens up new possibilities for engineers.
About ten years ago, Rogers introduced a PORON V0-M polyurethane for the HEV market, but it was firm er, halogenated, and limited in its range of use. PORON 40V0 foam represents the next generation: it is halogen-free, softer, more versatile, and better aligned with today’s environmental and design requirements.
Customer pull came from several directions. Data centers and automotive electronics were among the earliest drivers, but we also see strong interest in battery energy storage systems (BESS), HVAC, and charging infrastructure.
It really depends on the application. If the design requires extreme high-temperature stability or best-in-class water sealing, silicone is still the right choice . But if the key need is UL 94 V-0 compliance combined with softness, reliability, and cost effectiveness, PORON 40V0 foam is an excellent option.
The first step is to request a sample and review the technical data sheet. From there, our Solution Center, Sales Engineers, and Technical Service Team can help evaluate specific applications and ensure the right design decisions are made.
PORON 40V0 foam expands the Rogers flame-rated polyurethane portfolio with a solution that combines UL 94 V-0 compliance, siloxane-free and halogen-free chemistry, softness, compressibility, and proven long-term reliability.
Published on Sep 09, 2025
