Lightweight Train Interior Materials
Ecological considerations have become of increasing importance in the railway market. In the design of rolling stock this translates in a.o. the use of novel materials which offer light weight solutions and which are recyclable. New thermoplastic materials are used to reduce weight in the manufacturing of railway cars, without limitations on design or durability. Covestro AG (formerly Bayer MaterialScience) offers polycarbonate (Makrolon®) and polycarbonate blend sheets (Bayblend®) which open up new opportunities for designers and engineers of rolling stock. Focused R&D has resulted in new materials which can comply with the diverse fire regulations in vigour around the globe. As one of the world’s leading manufacturers of polycarbonate, Covestro AG (formerly Bayer MaterialScience) has a special know-how regarding extrusion processes, uses high-quality raw materials and a stringent quality management system to ensure the comprehensive control of all of its operations.
Lightweight, Impact Resistant Train Windows in Polycarbonate
Makrolon® polycarbonate sheets are half the weight of glass, yet almost unbreakable. Makrolon® is backed by a warranty against breakage, which virtually eliminates unplanned maintenance of rolling stock for cracked or broken windows. Even in case of vandalism the carriages can be kept in use until the next scheduled maintenance, because Makrolon® will not break. Worries about ageing and scratching are no longer an issue: an advanced coating technology makes Makrolon® sheets resistant against weathering and abrasion. At the same time they are lightweight so energy costs are reduced throughout the lifespan of the train.
Lightweight Railcar Interiors in Bayblend®
Bayblend® sheets can be thermoformed into ceiling panels, window masks, seat backs, and many other applications. Depending on the requirements, different material grades are available. Bayblend® MTX is the newest development, which complies with EN 45545-2 HL2 requirements for interior components such as ceiling panelling, side walls and seat backs. Bayblend® MTR is a highly impact resistant and rigid PC / ABS blend developed for the interior trim in railway vehicles with focus on the US market. The product satisfies the most stringent requirements with regard to fire behaviour, smoke density and toxicity such as Docket 90A/ASTM E 162 (radiation test on the fire behaviour of floor coverings) and Docket90A/ASTM E 662 (smoke density). Bayblend® FR3030 sheets are made of a halogen-free, flame-protected, highly impact-resistant PC / ABS blend. They satisfy stringent fire protection regulations for use in public transport vehicles (NF F16-101, DIN 5510). Covestro AG (formerly Bayer MaterialScience) offers a versatile range of Makrolon® sheets (PC) and Bayblend® sheets (PC+ABS) for a variety of applications. All grades are available in almost any colour and most can be offered with a special anti-graffiti surface, minimizing the risk of vandalism. Makrolon® and Bayblend® sheets offer a solution for mass transit interiors which meets all aesthetic, functional and engineering requirements.
The Advantage of Thermoforming for Railcar Manufacture
Thermoforming offers significant cost advantages for small to medium production runs when compared to injection moulding, sheet metal and aluminum components, PU or SMC systems. It is a highly cost-effective production process where thermoplastic sheets are formed under high temperatures. The result is medium to large-sized parts with very good surface quality, low weight and good rigidity. Savings compared with other manufacturing techniques can go up to 30% or even 50%, depending on the dimensions and the quantity of parts. Particularly the lower tooling costs are significant. Main advantages:
- Freedom of design
- Low tooling costs
- Small, medium and large quantities available
- Prototypes and pre-production
- Multi-layer sheet material
- Decorated material
- Covestro application managers can assist in finding the best thermoforming partner.
Global presence, local focus
Covestro AG (formerly Bayer MaterialScience) is easily accessible as it has a global network of companies, able to serve your needs in any region of the world. A designated team is at your service to give technical support. They can assist in selecting the products that will perfectly fit your needs.