Published
by Rogers Corporation
Elastomeric Material Solutions
UL 94 V-0 compliance is often associated with server housings and IT infrastructure. But engineers across many industries face the same design challenge: how to fill uneven gaps, protect sensitive components, and still meet flame safety requirements within compact electronic assemblies.
This is where soft, compressible UL 94 V-0 foams make a practical difference. PORON® 40V0 polyurethane foam was developed for a wide range of applications where flame safety and mechanical reliability must work together.
Compact electronic assemblies across industries face similar flame safety and mechanical design constraints. Image generated by AI. Property of Rogers Corp.
A common assumption in electronic design is that achieving UL 94 V-0 compliance requires materials that are relatively stiff, dense, or mechanically unforgiving. This perception is rooted in the historical availability of flame-rated materials that prioritized structural rigidity over compliance.
As a result, teams often compensate by tightening housings, increasing fastener loads, or accepting vibration and noise as unavoidable tradeoffs for flame safety. While effective in meeting compliance requirements, these approaches can introduce new challenges, including connector stress, air leakage, and inconsistent compression after thermal or environmental cycling.
Soft UL 94 V-0 foams offer an alternative approach by addressing flame safety requirements and providing mechanical compliance that helps accommodate tolerances, vibration, and long-term performance in tightly packaged systems.
Soft UL 94 V-0 foams are increasingly used in applications where flame safety must be balanced with tolerance absorption, vibration control, and long-term stability.
| Industry | Design Reality | How PORON® 40V0 Foam Helps |
|---|---|---|
| EV Charging & Automotive Electronics | Compact housings for modules and chargers are exposed to vibration and variable tolerances across assemblies | Cushions connectors and circuit boards without transferring vibration or overstressing components, maintains UL 94 V-0 compliance |
| Battery Energy Storage Systems (BESS) | Enclosures evaluated under UL 9540 and 9540A protocols must manage mechanical, thermal, and safety risks simultaneously | Soft UL 94 V-0 foam helps fill uneven module gaps without introducing excess force that could complicate qualification or reliability |
| HVAC Electronics | Control units and sensors often include uneven gaps and operate in warm or humid environments | Provides flame-rated seals that compress easily and remain stable through temperature and environmental cycling |
| Rail Electronics | Passenger systems must meet stringent flame and smoke requirements (such as EN 45545) while managing vibration and long service life | Combines UL 94 V-0 flame safety with cushioning and potential acoustic benefits in vibration-prone assemblies |
| Data Centers | Densely packed servers require fan sealing and board-level cushioning without increasing noise or stress | Balances UL 94 V-0 flame safety with acoustic absorption to help reduce fan-induced vibration and noise |
Across these applications, the challenge is rarely just meeting a standard. It is meeting the standard without compromising mechanical performance over time.
Before diving into material properties or datasheets, it helps to determine whether a soft UL 94 V-0 foam is the right class of material to evaluate. In many electronic assemblies, flame safety is addressed early in the design process. Mechanical behavior often becomes a concern later, during qualification testing or early production. A soft UL 94 V-0 foam may be worth evaluating when flame-rated materials are contributing to downstream issues such as:
If none of these conditions are present, a firmer flame-rated material may be sufficient. When they are present, soft UL 94 V-0 foams offer a way to address flame safety while improving performance. A Rogers Sales Engineer can help evaluate the right approach for your application.
Once a soft UL 94 V-0 foam is deemed appropriate to evaluate, engineers typically focus on several critical factors:
PORON® 40V0 polyurethane foam was developed with these considerations in mind, offering a balance of flame safety and mechanical flexibility across multiple industries and applications.
Flame safety is rarely the only design constraint. While UL 94 V-0 compliance is often addressed early in the design process, many performance issues emerge later when flame-rated materials are subjected to vibration, tolerance variation, and long-term compression.
Soft UL 94 V-0 foams allow engineers to meet flame safety requirements while maintaining mechanical compliance over time. This helps reduce stress transfer, preserve sealing performance, and support long-term reliability in compact electronic assemblies beyond the server rack.
Learn more about PORON® 40V0 material or request a sample to evaluate performance in your application.
Published on Feb 04, 2026
