Comfort, Safety & Durability

Cellular Silicone Foam Unique Features Inherently Fire Proof Zero Smoke Toxicity Zero Smoke Visibility Loss Wide Temperature Resistance (-50°C to +205°C) Low Heat Release Does not Melt Halogen Free

Free from Compression Set Uniform Load distribution Highly Comfortable & Durable

Highly Inert to Water UV Resistance No Odour Resistant to Solvents, Minerals & Oils.

About Advanced SiliconesAdvanced Silicones is a start-up venture that has specialized the development & manufacturing of Silicone formulations & products in different product segments including Cellular Silicones & Silicone Rubbers. After three years of dedicated research & development, ASPL is the first company in India that started the bulk production of Cellular Silicone foams.

An ISO 9001:2008 & ISO 14001 certified production facility is situated in National Capital region, Faridabad. The company possesses a wide range of test facilities that cover Mechanical, Thermal, Performance, Fire & Safety related tests for a wide range of industries.

Silicone Foam Installations

MRVC Driver SeatSupplied to BT

GS Coach Single Seater

LHB Chair Car

GS Coach Four Seater

LHB III Tier A/C

ABOUT SILICONES

Silicones are inert, synthetic compounds with a variety of forms and uses. Typically heat-resistant and rubber like.

They are generally used in Insulation, Sealants, Adhesives, Lubricants & Medical application mainly because of following properties:

• Higher Thermal Stability (-50°C to +205°C)• Excellent Fire resistance• Low Toxicity• Excellent compression set• Inertness to Water & Chemicals• Electrical Insulation

Silicones are Polymers with long chains ofalternating Silicon & Oxygen atoms withHydrogen & organic substituent's on Siliconbranches

Common Forms: Silicone Oil, Silicone Grease, Silicone Rubber, Silicone Resin, Silicone caulk.

Silicone Foam –Unique Features Inherently Fire Proof Zero Smoke Toxicity Zero Smoke Visibility Loss Wide Temperature Resistance (-50°C to +205°C) Low Heat Release Does not Melt Halogen Free

Free from Compression Set Uniform Load distribution Highly Comfortable & Durable

Highly Inert to Water UV Resistance No Odour Resistant to Solvents, Minerals & Oils.

FIRE & SAFETY

• Resistance to FireUIC 564-2: Class A ) (Railway Standard)DIN 5510-2: (S4, SR2, ST2; Fed < 1) (Railway Standard)UL94: V-0 (Electrical Standard)ISO 4589: >32 ISO 2440: Pass

• Smoke ToxicityNCD 1409: < 1 (Marine Standard)BSS 7239: Pass (Aviation Standard)

• Smoke Density/ Visibility LossUIC 564-2: Class A (Railway Standard)ASTM E 662: Pass (Aviation Standard)

• Heat Release RateEN45545-2: R21 (< 50 KW/m2) (Railway

Standard)

FIRE & SAFETY

High Intensity Fire Test

IMPORTANT FEATURS•Highly Fire Resistant•Does not melt into liquid•Extremely Low Smoke Density•Lowest Smoke Toxicity•Low Heat Release•Free of Halogens

FIRE & SAFETY

Suggestions for Safety Improvement

•Two Materials should not be compared by just one Standard

•Comparative Exercises on fire resistance to be conducted utilizing high intensity flame

•Material Melting & Gas transformation Temperature to be included

•Smoke Density to be compared at different fire temperatures

DURABILITY

New CushionUneven Cushion

Compression Set Test Truck Video

DURABILITY

Suggestions to achieve Higher Durability

• Conduct Automotive Standard IS: 7888; 70°C, 22 hrs; 0% Thickness Loss

100°C, 22 hrs; 0% Thickness Loss

• Comparison of practical installations in the coaches on more frequent basis

COMFORT

Important Facts for Seat Design of IR Coaches:

•Coaches Designed for Long & Overnight Journeys•Sleeping Option i.e. Sleeping Berths are essential•Less Scope for Contouring & Ergonomical designs•Flat Surface essential for sleeping

Factors Important for Comfort

•Indentation Force Deflection•Pressure Mapping

COMFORT

INDENTATION FORCE DEFLECTION International Industry Practice

(Indentation @ 40% compression)

2.5 – 5.0 kgf Bed Pillows, Thick back pillows

5.0 – 7.5 kgf Back Pillows, Upholstery Padding

7.5 – 10 kgf Very Thick Seat Cushions, Wraps

10 – 12.5 kgf Average Seat Cushions & Mattresses

12.5 – 15 kgf Firmer Seat Cushions & Mattresses

15 – 20 kgf Thin Seat Cushions & firm mattresses

> 20 kgf Shock Absorbing foams, Carpet underlays, Packaging etc

COMFORT

PRESSURE MAPPING

Computerized clinical tool for assessing pressure distribution.

COMFORT

Suggestions for improvement in Comfort

•Compare your specification of IFD with Internationally adopted values

•Test the durability of the material at these Optimum IFD values

•Pressure Map to be introduced in the specification

Infrastructure

Test Facilities

•Smoke Toxicity Test Chamber (NCD 1409)•Flammability Test Chamber (UIC 564-2)•Limiting Oxygen Index Tester (ISO 4589-2)•Smoke Visibility Loss Chamber (UIC 564-2)•Durability Fatigue Tester (IS: 7888)•Tensile & Elongation Tester (IS: 7888)•Indentation Tester (IS: 7888)•Steam Conditioning Chamber•Humidity & Temp Conditioning Chamber

• Hot Air Oven• Deep Freezer• Digital Viscometer• Compression Set Test Apparatus (IS: 7888)• Weighing Machines• Chemical Balance• Resilience Tester• Pressure Mapping Equipment

Advantages over Conventional Cushioning Materials

Higher Life & Cost SavingsSignificant Savings in Life Cycle CostMany Times Longer LifeLower Downtime of Coaches Savings in Infrastructure/Manpower Requirements for Retro fitment

More SafetyInherently Fire Proof(No other cushioning material meet its FST properties)Extremely Low Smoke Toxicity & Smoke Density(Lowest Smoke Toxicity & Smoke Density)Does not Melt into liquid

More Passenger Comfort/Better PerformanceHighly Durable & Long life at Optimum IndentationExcellent Compression Set(Zero Thickness Loss @ 50% Compression (70°C/22 Hrs & 100°C/22 Hrs)Retain Resilience & Indentation Hardness for much longer time(Does not loose its cushioning )Can be fabricated to make profilesGlobally accepted as premier cushioning material

PERFORMANCE COMPARATIVE

SILICONE FOAM PU FOAM Conventional

LIFE CYCLE COST

COMFORT/ (PERFORMANCE)

SAFETY

• INDEGENIZATION

• COST REDUCTION

• PRODUCT & PROCESS IMPROVEMENT

• POSSIBILITY OF OTHER APPLICATIONS

Opportunity means to us…….

Thanks!

Cost Comparison

Coach Type PL No. LPRPrice with

Silicone foam % DiffPrice with

Optimization % Diff

LHB AC Chair Car 33994109 761880 958609 1.26 876162 1.15LHB FAC 33600715 323866 547333 1.69 450173 1.39LW ACCW 33993828 558470 832121 1.49 723343 1.30LHB SCN 33600302 331789 560723 1.69 457868 1.38LHB GS 33600193 252242 423767 1.68 348093 1.38WGACCN 30616906 256009 433259 1.69 350732 1.37GS 30667446 130048 214937 1.65 178670 1.38

Smoke ToxicityNCD 1409

Gases to Detect:CO2 (Carbon Dioxide) CO (Carbon Monoxide) HBr (Hydrogen Bromide)HCL (Hydrogen Chloride)HCN (Hydrogen Cyanide)HF (Hydrogen Fluoride)NOx (Nitrogen Oxides)SO2 (Sulphur Dioxide)HCHO (Formaldehyde)CH2CHCN (Acrylonitrile)COCl2 (Phosgene)H2S (Hydrogen Sulphide)NH3 (Ammonia)C6H5OH (Phenol)

Flame Temp : 1100°C

EN 45545

Gases to Detect:CO2 (Carbon Dioxide) CO (Carbon Monoxide)HBr (Hydrogen Bromide)HCL (Hydrogen Chloride)HCN (Hydrogen Cyanide)HF (Hydrogen Fluoride)NOx (Nitrogen Oxides)SO2 (Sulphur Dioxide)

Furnace Temp : 600°C