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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 Silicones

Advanced 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 Seat

Supplied to BT

GS Coach Single Seater

GS Coach Four Seater

LHB III Tier A/C

LHB Chair Car

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 of alternating Silicon & Oxygen atoms with

Hydrogen & organic substituent's on Silicon branches

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 Fire

UIC 564-2: Class A ) (Railway Standard)

DIN 5510-2: (S4, SR2, ST2; Fed < 1) (Railway Standard)

UL94:

ISO 4589:

ISO 2440:

V-0 (Electrical Standard)

>32

Pass

Smoke Toxicity

NCD 1409:

BSS 7239:

< 1 (Marine Standard)

Pass (Aviation Standard)

Smoke Density/ Visibility Loss

UIC 564-2: Class A (Railway Standard)

ASTM E 662: Pass (Aviation Standard)

Heat Release Rate

EN45545-2: R21 (< 50 KW/m2) (Railway Standard)

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

High Intensity Fire Test

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

Uneven Cushion New 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

5.0 – 7.5 kgf

7.5 – 10 kgf

Bed Pillows, Thick back pillows

Back Pillows, Upholstery Padding

Very Thick Seat Cushions, Wraps

10 – 12.5 kgf

12.5 – 15 kgf

15 – 20 kgf

Average Seat Cushions & Mattresses

Firmer Seat Cushions & Mattresses

Thin Seat Cushions & firm mattresses

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

PRESSURE MAPPING

COMFORT

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 Savings

Significant Savings in Life Cycle Cost

Many Times Longer Life

Lower Downtime of Coaches

Savings in Infrastructure/Manpower Requirements for Retro fitment

More Safety

Inherently 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 Performance

Highly Durable & Long life at Optimum Indentation

Excellent 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 profiles

Globally accepted as premier cushioning material

PERFORMANCE COMPARATIVE

LIFE CYCLE COST

COMFORT/

(PERFORMANCE)

SAFETY

SILICONE FOAM PU FOAM Conventional

Opportunity means to us…….

INDEGENIZATION

COST REDUCTION

PRODUCT & PROCESS IMPROVEMENT

POSSIBILITY OF OTHER APPLICATIONS

Thanks!

Cost Comparison

Coach Type PL No.

LHB AC Chair Car 33994109

LHB FAC

33600715

LW ACCW

LHB SCN

LHB GS

33993828

33600302

33600193

WGACCN

GS

30616906

30667446

LPR

761880

323866

558470

331789

252242

256009

130048

Price with

Silicone foam

958609

547333

832121

560723

423767

433259

214937

% Diff

1.26

1.69

1.49

1.69

1.68

1.69

1.65

Price with

Optimization % Diff

876162

450173

723343

457868

348093

350732

178670

1.15

1.39

1.30

1.38

1.38

1.37

1.38

Smoke Toxicity

NCD 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

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