Institute of Polymers - - an experience in innovation projects implementation in the sphere of transport infrastructure and housing and communal service Tsybukov S.I. President of Institute of Polymers General director of SPA “KP” Meeting on issues of composite materials implementation, constructions and products made of them in the sphere of transport infrastructure, construction, housing and communal service under the guidance of the Vice Governor of St. Petersburg Golikov I.F г.

Structure 1. History – about the company 2. Innovation infrastructure 3. An experience of innovation projects implementation 4. The perspective of development and directions of possible cooperation

2001 – within the program “Transform”, the russian-german organization “Institute of Polymers” with the assistance of SKZ GmbH of Wurzburg city and Chamber of Commerce and Industry of St. Petersburg, realizes, together with leading russian and europian scientific centers and universities, the R&D, experimental development and innovation projects on the designed problems by Russian railways, SUE “Vodokanal of SPb” and by other enterprises – the presentation of Dynamic Tests Center of transport branch – joint project of Russian railways, State university of Polymers of St.Petersburg, Munich Technical University 2010 год – The opening of the Prototyping center of products made of composite materials and spraying the covering – mutual project of the Ministry of economic development, Administration of SPb and the enterprises of the Polymeric cluster 2011 год – Creation of the Center of green power - and resource-saving technologies within a uniform technological platform 2012 год – The opening of the Center of optical technologies and of precision casting for lighting devices and goods design and production 2013 год – Creation of the integrated distributed environment for optimization of development and implementation of goods made of constructional polymeric materials with using the systems of complex virtual modeling, the engineering analysis and preproduction History

Направления деятельности  Carrying out complex scientifically – research works in the field of high technologies with definition of technical requirements to a product and/or a detail, taking into account service conditions:  - selection of optimum materials for technical details production with the set properties, creation of new compoundings and production of new composite polymers;  - development of engineering, technological and standard documentation for equipment, technological processes and new details;  - carrying out the preproduction, development and operating tests of materials and products;  - development of technological processes of pilot production;  - output of pilot production lot with the set properties;  - development and realization of technological processes of batch manufacturing.  Gathering, analysis and systematization of information for constructional polymeric materials development and use of modern in world practice.  Carrying out and participation in scientific and practical seminars about the modern constructional polymers, technologies of their processing and use directions.. 25 patents are issued by results of the performed works Strategic direction of development Creation of the distributed center of dynamic tests of transport branch International innovative polymeric center Nanocenter of polymeric materials and covering

Материалы Technologies Материалы Modeling R&D (Research and Development) Tests Equipment Materials Companies Technologies, materials, equipment, contracts, test report, reports, passports, data of computer simulation, etc. Uniform Technological Platform of Polymeric cluster Integration with UTP All-Russian Research Institute of Aviation Materials Innovation Infrastructure

The integrated distributed environment for optimization of development and implementation the products made of structural polymeric materials  The integrated information environment (IIE) - set of the distributed databases containing data of product, the production environment, resources and the enterprise processes, providing correctness, relevance, safety and availability of these production- economic activity subjects, which are participating in life cycle realization of production and creation of engineering projects.  IIE by request of Plant “KP” is made by Institute of polymers. ИРС Preliminary Specification Product Design and modeling PrototypingEquipment design and modelling Equipment productionPreproduction Pilot batch of products Preproduction and full-scale test CertificationBatch manufacturingExploitation Innovation Infrastructure

Prototyping Center St.Petersburg NEW ORDER DETAILS DESING GROWING OF PROTOTYPE DETAIL PRODUCTION MOULD TESTING MOULD PRODUCTION MOULD DESING MOULDING IN SILICONE FORMS Prototyping center can solve the next tasks: Design of engineering documentation; Modification of engineering documentation; Design and correction of 3D models of products according to made drawings; the transference of engineering documentation in the electronic 2D form - drawings and 3D-models; creation of electronic catalogs of engineering elements and of products; creation of photorealistic images; volumetric scanning of objects; production of details polymeric prototypes; creation of silicone molding forms; production of a small lot of products (molding in silicone forms); Design and moulds manufacturing The analyse of mould leaking and material science; production of prototypes and small production lot on the equipment with programmed numerical control; ; measurement and control of the received prototypes; Innovation Infrastructure

Modern requirements to energy saving By some estimates, inefficient use of energy leads to 40% loss of all produced energy. In recalculation on equivalent fuel this quantity can be possible to compare to oil export volume (400 million t.). Thus, the main consumer is the fund of residential buildings, about 45% of produced or supplied energy is spent for their heating. In November, 2009 in the Russian Federation the Federal Law was adopted “About energy saving and increasing of power efficiency", including package of measures, providing for consumers opportunity to save resources and to make a choice for power effective decisions and technologies. One of the purposes of the existing law is to increase the power efficiency of buildings and to use the energy saving materials at buildings construction.

Application of frost protection and waterproofing anti-freezing polymeric coverings for housing and communal services and water utilities covering the anti-icing coverings on roofs of buildings and constructions by paints of production "Pigment" enterprises and by the Russian Academy of Sciences of chemistry and silicates institute named after I. V. Grebenshchikov covering on attic premises the frost protection covering made of tough expanded polyurethane, developed by “Institute of Polymers” covering on peaks of buildings and constructions the anti-icing coverings made of composite materials on the basis of UHMWPE, developed by Central Research Institute “Prometey” and "Institute of polymers" covering on basements the waterproofing coverings made of composite materials on the basis of UHMWPE, developed by chemical faculty of St. Petersburg State University and by "Institute of polymers" + pre-preg of institute named after Ioffe + powder paints for shutoff valves. covering on basements frost protection and waterproofing anti- freezing polymeric coverings made of tough expanded polyurethane, developed by "Institute of polymers" Isolation of heating pipelines (the top pouring) Энергосберегающие осветительные приборы и система управления

Implementation of polymeric coverings in the sphere of housing and communal services and at the industrial enterprises for the purpose of increasing the operational characteristics, power - and resource-saving covering the internal surfaces of tanks by protective polymeric covering; Treatment of walls and technological apertures by method of a polymeric spraying; covering the polymeric covering on internal and external surfaces of new rings for water supply wells, sealing of seams at installation by a polymeric material; Facing by pre-pregs and by special paints the surfaces of wells, collectors and pipes; Covering on metal surfaces (shutoff valves, large-size metal products etc.) powder paints and polymeric composites; Waterproofing of the buildings bases and constructions by method of spraying a polymeric protecting covering; Spraying the anti-icing polymeric coverings and carrying out the works on thermal insulation of attics, basements of buildings and constructions ;

Polimeric coverings on basis of ultra high molecular weight polyethylene  Cooperation with the SSI "The joint institute of Belarus NAN mechanical engineering" on creation and tests the UHMWPE device of spraying on various types of surfaces by method of a gas-flame spraying.  Participation in the international project Science Link – which purpose is support and encouragement of innovations and business in the region of the Baltic Sea and strengthening the competitiveness of the region in a global context.  Joint participation with JSC “ADAMANT” in the project on creation of laboratory installation for specification of an nanodiamonds output and diamondlike substances output from oil production and oil processing waste on diamond cracking technology. UHMWPE can be applied for spraying the various coverings on a surface of machines details, mechanisms of the various branches equipment: Spraying the protective anticorrosive coverings on a surface made of various materials; Spraying an anti-freezing layer; Spraying an antibacterial coverings;

New constructive decisions in various elements are used: Noise protective screen Vibro-extinguishing rubber panels Vibro-extinguishing insert in rail web. Depending on tasks it is possible to apply various construtions.. One of the protective means against the noise of railway transport – were developed together with Baltic State Technical university “VOENVEH” named after Ustinov D.F. Noise-protective and vibroprotective constructions

Lighting engineering products of traffic safety systems of railway transport Diminutive traffic lights made of constructive polymeric material Task: to adapt a case design of the traffic light made of aluminum at the present time under a polymeric material. Requirements to product remain the same: resistance to impact, resistance to influence of environmental aspects etc. The design of a product has to be unified both under lamp, and under LED optical systems. Based on experience at creation of the integrated distributed environment it is possible to design and model the mast traffic lights, special multipurpose devices. ZEMAX CODE V

Implementation of the project on development and case manufacturing for a fan heater made of polymeric material Replacement of case metal parts by the polymeric: Energy efficiency of industrial production due to industrial process optimization of case parts and accessories production made of polymeric material.

PROJECTPERSPECTIVE supporting rollers of the ballast cleaner machine`s conveyor made of a new structural polymeric material production of technical details made of structural materials (USO-4 roller for a rail-sleeper lattice, etc.) the modified magnetoshunting isolation for isolating joints with composite joint bars (MShI) replacement of an isolating joint "helicopter" type made of polyamide on POM (approx. 6 million pieces) the details of friction system made of new structural polymeric material participation in programs of transport equipment producers localization diminutive traffic lights in cases made of structural polymeric material The center of optical technologies - mast traffic lights - transfer in municipal economy under sleeper shock-absorbers of variable rigidity for high-speed railroad switches of the project 2956 The center of transport branch prototyping transfer in municipal economy laying shock-absorbers of rail fastenings means of noise protection (the noise protection screen, vibroextinguishing panels, inserts in a rail neck) Spraying the coverings on metal surfaces (coach, noise protective screens) Spraying waterproofing, antibacterial coverings by various methods on concrete and metal surfaces for Water utilities and housing and communal services Transfer of technologies from transport branch to housing and communal services and Water utilities Development of Institute of polymers projects

The distributed design office on the basis of application the technologies of complex virtual modeling of the engineering analysis and optimization of developed products made of polymeric materials It support: Glosys-service / SolidWorks Russia Foreign partners Интегрированная распределенная среда Uniform technological platform Reverse engineering: SolidWorks / CompMehLab / and others. Design, prototyping, molds production, manufacturing of products Design and molds production: SPA MetMash others Other co-performers: Development and coordination of / production of LED optical systems / and others. Test centers and laboratories : TL plant КP / FBI Nizhny Novgorod SMC / and others Interacts with the international cooperation network on the basis of the Uniform technological platform and operates in the integrated distributed environment on the basis of the Center of prototyping of SPb. Head of organization Project manager Designer- performer Designer with the rights of checking Technologist with the rights of technological control Designer with the rights of compliance assessment System’s administrator Guest Registration electronic form of the object at a development stage Information fields of form Place in archive Approved Compliance assessment passed Technologically coordinated Checked Developed Indicators of the object status of planning General working area Connection of process participants to system Project managerSystem’s administrator Strengthened local working area Standard local working area Designer with system CAD 3D Ordinary users of MS Office

Thank you for your attention Saint-Petersburg, Smolyachkova st. 4/2, тел. (812) , факс: (812) , /