A JOURNEY OF COMBINING FIRE SAFETY AND DESIGN CRITERIA FOR ENGINEERING THERMOPLASTICS FOR RAILWAY INTERIORS FIRE BY: HILMAR PROTECTION BACKER OF ROLLING STOCK 2015 October 18-19 MARCH 2013 2015 BY: HILMAR BACKER
CONTENT ABOUT SABIC INTRODUCTION CASE STUDY: SEATING CASE STUDY: LIGHTING CASE STUDY: SIDE-WALL CLADDING NEW SABIC DEVELOPMENTS No. 1
WE ARE SABIC We are one of the world s leading manufacturers of chemicals, fertilizers, plastics, and metals. Since our founding in 1976, we have achieved rapid global growth. 2 nd largest global diversified chemical company* 88 th largest public company in the world* $ 50.4 billion Sales Revenues in 2013 $ 90.4 billion Total Assets in 2013 6 STRATEGIC BUSINESS UNITS: CHEMICALS PERFORMANCE CHEMICALS METALS FERTILIZERS POLYMERS INNOVATIVE PLASTICS * Forbes 2012 No. 2
RAILWAY INTERIORS Rail seat cover parts Anti-Grafitti interiors panels Transparent doors and deviders Railway Lighting Side-Walls / Ceilings Air-Ducting Rail seats Luggage racks Railway Connectors Cable Trunking Picture Source: All pictures used with customer permission No. 3
Functionality NEW TECHNOLOGIES LEXAN co-polymers Filled FR Polymer blends Functionalization through additives Polymer Addition of new building blocks yields PC co-polymer resins with new properties PRODUCT/PROCESS TECHNOLOGY No. 4
NEW TECHNOLOGIES STD. FR POLYCARBONATE OR FR PC/ABS: Loose & unstable char, Failing in Heat release & Smoke Density NEW MINERAL FILLED FR PC/ABS: More stable char formation, Improved HRR & Smoke density (HL2) NEW LEXAN CO-POLYMERS : Stable and compact char formation Leading to very robust Heat release and Smoke density results! (HL3) No. 5
SELECTING MATERIALS Plastics FRP Metal Cost + - + - + - Noise Reduction + + + + - - Design + + + - Design complexity + + + - In-colored (no paint) + + + - - - Easy replacable + - + Durability + + - + + Safety + - + - + - Regulation + - + + + Customization + - + + + + Repairability + - - + Depends by application and specific material use. No. 6
EXPERT TECHNICAL ASSISTANCE: OUR SERVICE EXCELLENCE Part design Assembly design Tooling design Process design Chemical compatibility data/testing Adhesive selection and testing Product development, specialized needs Weathering testing/color technology support Physical property testing/temperature extremes Regrind analysis Thermo-cycle testing FEA support Product/process development lab Design, Development, Testing and Processing Support No. 7
CASE STUDY: SEATING
MATERIAL DEVELOPMENT OF LEXAN TM FST3403 RESIN Railway Regulation EN45545-2:2013 Co-Polymer Development Grammer ICE-seating In-house Fire Testing 1400 1400 1400 1200 1200 1200 Smoke Density 1000 800 600 400 ` Smoke Density 1000 800 600 400 ` Smoke Density 1000 800 600 400 ` 200 200 200 0 0 200 400 600 Time (s) 0 0 200 400 600 Time (s) 0 0 200 400 600 Time (s) Final Part Mold Flow DOE s on burning behavior Picture Source: All pictures used with customer permission No. 9
VALIDATION BY CUSTOMERS Railway Regulation Co-Polymer Development Fire Testing Bombardier Mono-Rail Engineering Design Ease of installation Final Part Mechanical testing Mechanical requirements Picture Source: All pictures used with customer permission No. 10
ART TO PART EXAMPLE RAILWAY SEAT CUSTOMER CHALLENGE Bombardier was looking for a fresh new seating design for the seat banks of Sao Paulo s Innovia rail system. They were interested in a lightweight solution that would increase passenger comfort, durability and sustainability. SABIC SUPPORT Design optimization Montemeao was challenged to design for total cost of ownership Tool development assistance tooling assistance was required to allow aesthetics Processing support support was given to resolve any processing challenges Material certification pass on Americas Railway standard NFPA-130 Color recommendations any color possible Static, dynamic and impact load testing impact test and validation CUSTOMER WINS A new, injection-molded seat the reduced manufacturing costs Up to 15% lighter, reducing CO2 emissions vs. thermoset processing End of life recyclability Ease of maintenance and replacement Picture Source: All pictures used with customer permission No. 11
RESULTS Implementation at Bombardier Mono-Rail program in Sao Paolo Picture Source: All pictures used with customer permission No. 12
SABIC RESIN PORTFOLIO SABIC S THERMOPLASTIC RESINS FOR THE RAILWAY SEATS PRODUCTS KEY FEATURES LEXAN PC RESINS OPAQUE NEW LEXAN FST3403 Resin LEXAN FST3002 Resin High Flow EN45545-2 R6 / HL3 France NF F 16.101/102 Germany DIN-5510-2 Poland PN-K-02511 Americas NFPA-130 High Flow EN 45545-2 R6 / HL2 LEXAN EXL9330 Resin France NF F 16.101/102 CYCOLOY PC/ABS RESINS OPAQUE CYCOLOY CX7240 Resin France NF F 16.101/102 Germany DIN-5510-2 CYCOLOY C6600 Resin France NF F 16.101/102 Germany DIN-5510-2 No. 13
LEXAN RESIN SOLUTIONS FROM SABIC FOR INJECTION-MOLDED APPLICATIONS > LEXAN FST3002 RESIN A PC COPOLYMER SOLUTION OFFERING: > High-flow capabilities > Easy design and production of large parts NEW! EN 45545 COMPLIANT R6 HL2 > Consistent surfaces with no marks, grainage, stains or flow lines > HL2 level of EN 45545 compliance for seating components such as seat base and back shells and seating side panels No. 14
CASE STUDY: LIGHTING
VALIDATION WITH CUSTOMERS Transparency Diffusion Haze Transmission Etc. Railway Regulation Customer Needs Mapping Extrusion trials EN45545 acc: class HL3-R4 Customer validation Final Part by Elkamet Certification Mechanical behavior Picture Source: All pictures used with customer permission No. 16
SABIC PORTFOLIO SABIC S THERMOPLASTICS FOR THE RAILWAY LIGHTING PRODUCTS KEY FEATURES LEXAN 2034 Resin EN45545-2 R4/HL3 NF F 16.101/102 DIN-5510-2 EXTRUSION TRANSPARENT OPAL WHITE LEXAN PC RESINS LEXAN EX9332T Resin EN45545-2 R4 /HL3 NF F 16.101/102 DIN-5510-2 EXTRUSION DIFFUSION SATIN EFFECT NEW LEXAN FXD9332T Resin EN45545-2 R4 / HL3 LEXAN PC SHEETS EXTRUSION TRANSPARENT OPAL WHITE LEXAN F2000 Sheet EN45545-2 R4 No. 17
LEXAN RESIN SOLUTIONS FROM SABIC FOR LED LIGHTING APPLICATIONS > LEXAN FXD9332T and LEXAN EX9332T RESINS COMPLIANT MATERAIL SOLUTIONS WITH EN 45545 AND THE EU BUS STANDARD EU 95/28/EG. > LEXAN FXD9332T is a new diffusive resin suitable for creating covers for LED light sources as its inherent satinlike surface texture helps to scatter light and eliminate hot spots. The material is well suited to be used in profile extrusion. > LEXAN EX9332T is a transparent resin that offers high transmission of 89% over a wavelength of 450-750 nm. It is suitable for applications that require very bright LED lighting. It has a narrow transparent variance specification, eliminating strong color variation during a production run, reducing lot-to-lot variations while helping to increase manufacturing efficiency. NEW! EN 45545 COMPLIANT R4 HL3 No. 18
CASE STUDY: SIDE-WALLS
MATERIAL DEVELOPMENT Railway Regulation Co-Polymer Development Fire Testing Interiors side-wall Staining / Anti-Grafitti Norm testing Color options Thermoforming Scratch performance Picture Source: All pictures used with customer permission No. 20
ULTEM & LEXAN SHEETS SABIC S THERMOPLASTIC SHEETS FOR THE RAILWAY INTERIORS PRODUCTS KEY FEATURES PEI OPAQUE ULTEM R16SG29 Sheet High Modulus Meet EN45545 LEXAN H6000 Sheet High Modulus LEXAN H6500 Sheet High Modulus M1 F1 2-5mm, Meet EN 45545 PC/ABS BLEND OPAQUE LEXAN H6200 Sheet LEXAN H6200M Sheet GERMAN DIN 5510 M1 F2 NEW LEXAN KH6500 Sheet NF F 31-112 (G1) Anti-graffiti DIN 5510 & US - NFPA 130 NEW LEXAN KH6200 Sheet NF F 31-112 (G1) Anti-graffiti DIN 5510 PC CO-POLYMER OPAQUE NEW LEXAN XHR6200 Sheet Meet EN 45545 OPAQUE LEXAN F6000 Sheet Fulfilling DIN5510 PC TRANSPARENT LEXAN F2000 Sheet LEXAN MARGARD MR5FR Sheet Meet EN45545 Clear & Opal White Both Side Coated Sheet No. 21
LEXAN SHEET SOLUTIONS FROM SABIC ROBUST, LOW GLOSS PRODUCT FOR ANTI - GRAFFITI > LEXAN KH6500 SHEET A PC/ABS SOLUTION OFFERING: > Graffiti resistance - French NF F 31-112 (G1) anti-graffiti norm > Environmentally responsible non-chlorinated and non-brominated fire safety - German DIN 5510-2:2009 > Compliance with U.S. fire regulations > NFPA 130 - Fixed Guideway Transit and Passenger Rail Systems > ASTM E162 - Surface Flammability of Materials Using a Radiant Heat Energy Source > ASTM E662 - Specific Optical Density of Smoke Generated by Solid Materials > ASTM E1354 - Heat and Visible Smoke Release Rates for Materials and Products Using an Oxygen Consumption Calorimeter > SMP 800C - Toxic gas sampling and analytical procedures > Easy manufacturing and thermoforming > Low gloss aesthetics after thermoforming > Durability, high stiffness and impact resistance > Lightweight and design freedom > POTENTIAL APPLICATIONS: Railway interior seats and tables, walls and other large rail interior parts NEW! GERMAN DIN US NORM COMPLIANT No. 22
LEXAN SHEET SOLUTIONS FROM SABIC COST EFFICIENT PRODUCT SOLUTION FOR ANTI - GRAFFITI > LEXAN KH6200 SHEET A PC/ABS SOLUTION OFFERING: > Graffiti resistance - French NF F 31-112 (G1) anti-graffiti norm > Environmentally responsible non-chlorinated and non-brominated fire safety - German DIN 5510-2:2009 > Durability and impact resistance > Lightweight > Easy manufacturing > Lower system cost > Design freedom NEW! GERMAN DIN COMPLIANT > POTENTIAL APPLICATIONS: Rail carriage interior walls, rail interior panels, window frames, interior ceiling and other large rail interior parts No. 23
CONTACTS Hilmar Backer Industry Marketing Manager Mass Transportation SABIC Plasticslaan 1 PO Box 117 4600 AC Bergen op Zoom hilmar.backer@sabic.com Torben Kempers Regulatory Expert Mass Transportation SABIC Plasticslaan 1 4612 PX Bergen op Zoom The Netherlands E: torben.kempers@sabic.com www.sabic.com Stephan Plomp Industry Marketing Manager Railway Interiors SABIC Plasticslaan 1 4612 PX Bergen op Zoom The Netherlands E: stephan.plomp@sabic.com www.sabic.com No. 24
DISCLAIMER DISCLAIMER: THE MATERIALS, PRODUCTS AND SERVICES OF SAUDI BASIC INDUSTRIES CORPORATION (SABIC) OR ITS SUBSIDIARIES OR AFFILIATES ( SELLER ) ARE SOLD SUBJECT TO SELLER S STANDARD CONDITIONS OF SALE, WHICH ARE AVAILABLE UPON REQUEST. INFORMATION AND RECOMMENDATIONS CONTAINED IN THIS DOCUMENT ARE GIVEN IN GOOD FAITH. HOWEVER, SELLER MAKES NO EXPRESS OR IMPLIED REPRESENTATION, WARRANTY OR GUARANTEE (i) THAT ANY RESULTS DESCRIBED IN THIS DOCUMENT WILL BE OBTAINED UNDER END-USE CONDITIONS, OR (ii) AS TO THE EFFECTIVENESS OR SAFETY OF ANY DESIGN OR APPLICATION INCORPORATING SELLER S MATERIALS, PRODUCTS, SERVICES OR RECOMMENDATIONS. UNLESS OTHERWISE PROVIDED IN SELLER S STANDARD CONDITIONS OF SALE, SELLER SHALL NOT BE RESPONSIBLE FOR ANY LOSS RESULTING FROM ANY USE OF ITS MATERIALS, PRODUCTS, SERVICES OR RECOMMENDATIONS DESCRIBED IN THIS DOCUMENT. Each user is responsible for making its own determination as to the suitability of Seller s materials, products, services or recommendations for the user s particular use through appropriate end-use and other testing and analysis. Nothing in any document or oral statement shall be deemed to alter or waive any provision of Seller s Standard Conditions of Sale or this Disclaimer, unless it is specifically agreed to in a writing signed by Seller. Statements by Seller concerning a possible use of any material, product, service or design do not, are not intended to, and should not be construed to grant any license under any patent or other intellectual property right of Seller or as a recommendation for the use of any material, product, service or design in a manner that infringes any patent or other intellectual property right. SABIC and brands marked with are trademarks of SABIC or its subsidiaries or affiliates. 2013 Saudi Basic Industries Corporation (SABIC). All Rights Reserved. Any brands, products or services of other companies referenced in this document are the trademarks, service marks and/or trade names of their respective holders. No. 25