What Are PORON Gaskets and How Do They Compare to Others?

If your product sample failed, would you fall to your knees shouting, “NOOO! I knew I should have used PORON in this gasket!”... or not? 

Probably not. But there could be some truth to this reaction.

PORON foam is a highly durable gasketing material that can insulate and absorb shock or vibrations from moving parts. Its specialized variations make it a reliable choice for many different applications. 

Over the years, Strouse has prototyped and built many PORON foam designs, including gaskets and sealing strips. 

Learning about PORON's properties is crucial when choosing a gasket material. Keep reading to find out its specifications and compare PORON to its alternatives. 

What is a PORON Gasket? 

A PORON gasket is a foam polyurethane gasket often used to seal water, air, or chemical solutions. It is resistant to deformation and holds its shape, even in applications with moving parts. 

PORON gaskets are typically cut from foam rolls using laser, flat bed, or rotary die cutting processes. 

WHAT MATERIAL IS PORON?

PORON foam is a brand of microcellular polyurethane invented and sold by the Rogers Corporation. While it may appear to be a closed-cell foam, its microcellular structure allows it to bar water from entry. Rogers PORON comes in open- and semi-closed-cell foam variations customized to meet application needs. 

These are the material specifications for the core standard PORON products (pulled from the PORON® Industrial Polyurethanes Material Selection Guide):

• Density ranges from 104kg/m³ (6.5lb./ft³) to 480kg/m³ (30lb./ft³).
• Thicknesses range from 0.3mm (0.012”) to 12.7mm (0.5”)

THE CHARACTERISTICS OF PORON FOAM

1. HIGH ENERGY ABSORPTION

Thanks to their compression set resistance, many PORON materials can absorb high energy levels and spring back. Any impact energy is absorbed and distributed throughout the material to prevent damage. 

For instance, PORON ShockSeal materials may reduce impact force by up to 4x compared to other brands, making them ideal for gasketing applications designed for impact protection, such as handheld devices or industrial applications. 

2. HEAT AND CHEMICAL RESISTANT

PORON has a wide temperature range of around -40°F to 194°F (-40°C to 90°C) and 250°F (121°C) intermittent use, which suits a broad range of applications. This material maintains its structural integrity during temperature fluctuations and meets stringent flammability UL ratings.

In addition, many PORON foams offer substantial chemical resistance against organic and automotive fluids.

3. FLEXIBILITY 

While highly durable, PORON is also flexible and easily compressed, which helps it perform gap filling, gasketing, and noise reduction. The compression force is listed on PORON data sheets, which also typically list the compression force deflection (CFD) for every material. 

Comparing PORON to Other Gaskets

It wouldn’t be an informative article unless we considered alternative gasketing foams, so let’s discuss the pros and cons of your different options.

PROS

• Polyurethane foams can be cheaper than PE, neoprene, or silicone depending on the thicknesses, coatings, vendor, and MOQ (minimum order quantity).
• Lightweight with excellent abrasion resistance (for applications involving more friction) 

CONS

• Polyurethane emits toxic chemicals upon decomposition, which is why certain industries are phasing it out of use
  • Other materials, like silicone foams, can be thermally decomposed without emitting harmful chemicals. 

ALTERNATIVE GASKET MATERIALS

• • Silicone is a better choice than PORON for applications that involve fire-proofing or are sensitive to added health risks.
  • You can find both open or closed-cell silicone foam

2. EPDM gaskets: serve as electrical insulators that resist weathering, wear and tear, and high temperatures. Similar to polyurethane, EPDM is UV, weathering, and heat resistant.

• • EPDM’s operating temperature is significantly higher than PORON’s (-50°F to 300°F [-45°C to 150°C])
  • EPDM is a closed-cell material that offers specific sealing properties that PORON cannot as an open-cell foam

• • Neoprene has a higher operating temperature than PORON (-40°F to over 200°F [-40°C to over 110°C])
  • Neoprene is a closed-cell material that offers specific sealing properties that PORON cannot as an open-cell foam

Of course, plenty of other gasket materials may better suit your project than those listed, so make sure you research or contact a converter for their expertise before you begin manufacturing a product.  

Finding PORON Gaskets

Now that you’ve reviewed the PORON specifications, you should have a better understanding of whether it fits your gasket application. 

So, where can you find PORON? If you’re seeking out PORON foam directly, you can call Rogers Corporation or a distributor to see what they have available. However, if you’re looking for custom gaskets, an adhesive converter is likely the best option. 

A preferred converter will inspect your part drawing and help build an efficient production process to manufacture high-quality PORON gaskets that match your needs. 

Strouse’s team will guide you through the product development process to ensure your material and design are fully optimized for the speed and accuracy of a one-pass production process. 

Lastly, you can learn more about the different types of gasket material in our Learning Center.