UL 94 V-0 Foams for Data Centers: Managing Noise, Heat, and Fire Risk

Published by Rogers Corporation
Elastomeric Material Solutions

The heartbeat of every data center is its servers - hundreds or thousands of boards, fans, and power modules operating continuously to keep critical systems online. As computing power increases, system density rises with it, compressing thermal, mechanical, and safety margins inside server enclosures.

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Meeting these demands requires more than airflow optimization or fan upgrades. It requires materials that protect sensitive electronics, seal against vibration and air leaks, and meet stringent flame safety standards without compromising reliability or acoustic comfort.

That’s where PORON® 40V0 polyurethane foam comes in.

The Growing Challenge: More Power, Less Space

Data centers are evolving rapidly. Artificial intelligence (AI) workloads, high-speed networking, and edge computing are driving hardware that runs hotter, packs more components into smaller volumes, and operates continuously. Inside these systems, space is limited, and safety margins are narrow.

Engineers must balance:

• Thermal Management: Prevent heat buildup at the CPU and GPU chips.
• Acoustics: Reduce fan noise that contributes to mechanical vibration and unsafe occupational levels.
• Mechanical Reliability: Protect boards and connectors from vibration or stress.
• Flame Safety: Meet UL 94 V-0 and IEC 62368-1 requirements for electronics.

Traditional foams can handle one or two of these challenges, but rarely all four.

A New Approach: Soft, Flame-Rated, and Data-Center Ready

PORON 40V0 foam was engineered for high-density electronic environments where safety, sealing, and vibration control must all coexist. It combines UL 94 V-0 compliance with soft compressibility and long-term sealing performance, helping engineers protect electronics while meeting demanding safety and reliability targets.

How PORON 40V0 material helps in server and network equipment:

• Flame safety: Certified UL 94 V-0 down to 3 mm, helping meet internal OEM material specs.
• Noise control: Absorbs low-frequency vibration and fan noise, improving acoustic comfort in rack rows and test labs.
• Soft compressibility: Fills gaps around fans, trays, and housings without stressing boards or fasteners.
• Stress-relaxation resistance: Maintains consistent sealing force through continuous temperature cycling.
• Siloxane-and halogen-free: Reduces contamination risk on optics, sensors, and circuit boards.

Applications in Data Centers

1. Fan and Blower Seals: PORON 40V0 foam reduces leakage around high velocity air paths and absorbs fan noise that can contribute to vibration that can affect hard drive performance.
2. Power and Data Gasketing: Soft compression behavior ensures tight repeatable seal around enclosure penetrations without deforming the housing or stressing fasteners.
3. Server and Rack Vibration Isolation: Maintains consistent compression and cushioning throughout the entire life of the system to ensure vibration doesn't create read/write errors in hard drives.
4. Acoustic Baffles and Panels: Combines noise absorption and flame safety in areas where airflow, vibration, and heat intersect.

Why Flame Safety Matters in the Server Rack

While catastrophic fire events in data centers are rare, the risk of localized ignition - from short circuits, overheated connectors, or failed power modules - remains real. Using UL 94 V-0 materials for internal foams and seals ensures they self-extinguish quickly and do not add fuel if a fault occurs. Read more on UL94 flame ratings.

For many OEMs, this is not just good practice; it’s a qualification requirement. Leading data center equipment manufacturers now specify V-0 foams exclusively for internal gasketing, making PORON 40V0 foam a natural fit.

Balancing Compliance and Cost

Historically, silicone foams were the go-to choice for UL 94 V-0 compliance. They perform well in high-temperature or outdoor environments, but for indoor server applications, they can be over-specified and may be costly.

PORON 40V0 foam bridges that gap by providing the flame performance of silicone in a soft polyurethane, making it easier for engineers to meet specs in a cost-effective way.

Key Takeaway

In today’s data centers, every watt counts and every material matters. A foam that delivers UL 94 V-0 safety, soft compressibility, acoustic absorption, and reliable long-term performance can make a measurable difference in uptime, compliance, and user experience.

PORON® 40V0 polyurethane foam was built for this balance - protecting critical systems while simplifying design decisions for engineers. Request a sample to evaluate PORON 40V0 foam in your next server or power-electronics design.

Published on Jan 08, 2026

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