SABIC to showcase advanced material solutions well-suited for railway applications at Innotrans 2022.

• Innovative LNP™ FST copolymer resins, including bio-based versions, could be used for railway interiors in compliance with strict Fire, Smoke & Toxicity standards
  
• New FST compliant LEXAN™ sheet series for potential use in thermoforming of large and lightweight Railway Interior components
  
• Novel LNP™ THERMOCOMP™ AM compound as a candidate for Pellet-Fed Additive Manufacturing (PFAM) of large exterior and interior railway applications

SABIC, a global leader in the chemical industry, will introduce several innovative new material solutions well-suited for railway components at InnoTrans 2022 in Berlin from its Specialties and Functional Forms business divisions. The joint exhibit at Booth 332 in Hall 5.1 will feature the company’s latest developments in halogen-free flame-retarded, light-weighting and more sustainable products with potential for use in injection molding, extrusion, thermoforming and additive manufacturing of demanding interior and exterior railway applications. The focus will be on seating and interior cladding components in compliance with strict Fire, Smoke & Toxicity (FST) standards in the railway industry.

Spearheading SABIC’s material innovations on display at the show, the Specialties team will present four new LNP FST copolymer resins that target train seating applications designed to meet EN 45545 R6-HL2. The range includes an injection molding and an extrusion grade as well as a bio-based version of each with 55 percent renewable feedstock from crude tall oil and other waste products. The chemistry of these FST copolymers is the result of a major technological breakthrough that achieves full compliance with the harmonized European rail fire protection standard without the use of halogenated or brominated flame retardants. A complementary FST extrusion product, also available in a bio-based version, has been developed to meet EN 45545 R1-HL2 for horizontal and vertical interior claddings, including ceilings and walls.

Key benefits of all these LNP FST copolymer resins include high modulus, long-term durability, excellent strength-to-weight ratio for significant weight savings, colorability to avoid secondary painting, and efficient processing without secondary operations. The greater design freedom of these products vs. thermosets, stamped metal or aluminum can also facilitate part integration for further enhanced cost effectiveness.
In addition, they exhibit excellent chemical resistance, which simplifies graffiti removal and regular cleaning without the risk of environmental stress cracking. Beyond paint elimination, light-weighting and recyclability, the bio-based grades expand the sustainability benefits by mitigating fossil depletion and generating 33% lower carbon emissions vs. fossil counterparts, as validated in an Intergovernmental Panel on Climate Change (IPCC) CO2 equivalent analysis.

Another innovative polymer solution, new LEXAN™ sheet series H6700, H6800 and H6900, providing light weight, durability, aesthetics and compliancy to all major railway FST standards, including EN 45545-2, UIC 564-2, TB/T 3237, NFPA-130, DIN 5510-2 and NCD 1409. Well-suited for a wide range of large thermoformed railway interior applications, such as wall and seat claddings, kickboards, window frames, partition walls, lavatory modules and ceilings. Compared to fiber-reinforced plastics (FRP), the new LEXAN sheet series offers up to 30% weight savings per part and vehicle. As an engineering thermoplastic material, it provides superior freedom of design for cost-effective part integration and consolidation, which gives it a perfect fit as FRP and aluminum replacement. It delivers outstanding surface quality, with inherent anti-graffiti properties to make everyday maintenance easier. By eliminating the need for painting and/or coating, it also facilitates the end-of-life recycling of applications in a more circular and sustainable plastics economy.

Extending the manufacturing options for customers in the railway industry, SABIC’s novel LNP THERMOCOMP™ AM DC0041XA51 compound opens a completely new and disruptive path to both interior and exterior rail components. The 20% carbon fiber reinforced material targets the printing of large and medium-sized parts in Pellet-Fed Additive Manufacturing (PFAM). It can be processed at high printing speeds and relatively moderate temperatures, delivering good dimensional stability with low warpage. As a non-halogenated product, it is one of the first PFAM capable compounds to comply with both EN45545 and U.S. NFPA 130. Potential applications include rail guards and bumpers as well as interior claddings, ducts and seating components. The material is well-suited for printing large replacement parts at minimized lead limes. The lower density of the carbon vs. other structural fibers also enables the design of thinner and lighter parts that can contribute to net-zero carbon goals.

“Railway operators are constantly seeking new material solutions to meet the challenges of increasingly stringent safety and environmental regulations while reducing their cost of ownership and offering their passengers a more satisfying traveling experience,” says Marco Dalmino, Director, Customer Fulfillment EMEA of SABIC’s Specialties BU. “We are determined to deliver the state-of-the-art material technology to meet these needs at the forefront of the industry, helping our customers maximize the safety, sustainability, profitability and appeal of rail travel.”

SABIC will showcase its advanced new product solutions for the railway industry during InnoTrans 2022 from September 20 to 23 in Berlin, Germany, at Booth 332 in Hall 5.1. For more detailed product information, including each product’s potential uses, read the illustrated press releases on LNP ELCRES FST copolymer resins for seating applications, LNP ELCRES FST2734E copolymer for rail claddings, LEXAN H6700 sheet for large thermoformed interiors, and LNP THERMOCOMP AM DC0041XA51 compound for additive manufacturing of railway components.