Document 3JNJwjkrGez59qmdQnkRynDgn
FILE NAME Corning OC
DATE 1967 Oct 23
DOC OC306
DOCUMENT DESCRIPTION Memo RE - Kaylo Product Development with Clean Typed Copy
Mr. J. H. Thomas Toledo R. F. Shannon Granville KAYLO PRODUCT DEVELOPMENT
October 23 1967
Mr. R. J McEvoy Granville
Pi Pfeifer sent me word last week you wanted to talk about the replacement of asbestos program I attempted to contact you several times last week plus on Monday of this week without success As you know I was in Berlin
all of last week working on plant process problems
To follow on your request to move promptly on the evaluation of epoxy coated Fiberglas yarns Pi Pfeifer asked Bob Wong for help in getting for us a supply of such yarns for our evaluation in Kaylo As soon as the Chemistry Lab produces the yarns for us we will evaluate in Kaylo and
send you the results
The epoxy in cement miniature
coated yarns reported are in reality 12 end
fishing rods They
recently as being used to good advantage rovings coated with epoxy resin to form
are quite stiff about the size of tooth
to picks and about 1-1 3 inches long Mr. McEvoy agreed to my accompany
ing Mr. Potts of FIM Division in New York to Rensselaer Polytechnic Institute on Wednesday October 25 to discuss the concept with Professor
Klink the inventor
The program directed toward replacing asbestos in Kaylo is complicated by 1 the huge investment we have in the SID cylinder pan pouring process at Berlin 2 the need for additional plant capacity and 3 problems which must be answered as to type of process to use in the new facility
before expansion is undertaken Questions to be answered include 1 do
we expand Berlin 901 now in Toledo or do we build a new plant and 2 if we build a new plant do we install the SID cylinder pan pouring process
or another process yet to be determined
I cannot say at the moment with any assurance we will be successful in
developing another type of reinforcement preferably glass which can adapted to the SID cylinder pan pouring process The best odds I can
at the moment are 50/50 In any case the problem won't be solved in
be
project
a week
or month In fact we will be lucky to carry the program to a plant trial stage after a year's effort
In view of the fact the probability of finding another reinforcement which can be used in our present process is at the best 50/50 do we
also direct some of our effort toward a new process and if so what
on process At the moment there are no high temperature insulations the
market which do not contain at least some asbestos To the best of our
knowledge the only asbestos free product on the market in recent years
was OCF's Multitemp Do we attempt to improve Multitemp My answer would
Multitemp be The
was ill conceived
concept of post impregnating a prebonded product
It does not lend itself to adequate profit margins
354
Mr. J. H. Thomas
-2-
October 23 1967
Instead if the decision is to develop a product based on glass fibers I would recommend we work on an inorganic bonded glass fiber composite
which can be produced in a step operation possibly via a modified
version of the filter press process
We must not forget the bonded aggregate type product Careytemp is a bonded perlite reinforced with glass and asbestos fibers If Philip Carey could solve their breakage problem Careytemp would become the best high
temperature product on the market I believe an OCF version of such a
product containing 100 percent glass reinforcement would have a high probability of success As you know this is the program which Marketing
canceled on us year after year in the past
Now that I have given you a brief insight as to my thoughts as to where we go from here I would like to suggest for your consideration the follow-
ing program Initiate a hard hitting intensive search for a fiber substitute for asbestos The effort should be directed mainly toward glass fibers We should not however close our eyes to other ceramic fibers which become commercially available in the meantime We should also initiate
an exploratory program directed toward checking the feasibility of developing a glass reinforced bonded aggregate or an inorganic bonded high temperature glass fiber product Multitemp via a different process
Your first thoughts to the above may be we are spreading our activity too much We should instead decide on one program Under ordinary circumstances
I would agree with the idea of concentrating on one approach However
we must recognize the fact that if we direct all our efforts toward finding a substitute for asbestos and if not successful we could find ourselves
with two plants Berlin and the new one to be built equipped with a process
requiring asbestos On the other hand if the decision is not to continue
looking or high
a death ment in million
for a substitute for asbestos but start to develop a bonded aggregate
temperature glass fiber a la Multitemp product we are giving sentence to Berlin the SID cylinder process and the huge investthe pan pouring process Also we will face an outlay of 6 to 10
just to revamp Berlin to the new process
What are the chances of technical success I would guesstimate 50/50 of replacing asbestos in the pan pouring process 90 percent for a glass reinforcement bonded aggregate product and about 80 percent for a step process Multitemp type product having a 30+ percent gross margin
What need
really bothers me is timing
manpower and facilities At
To the
carry out any type of program we will moment I am down to two technicians
and about 1/2 the space allocated to Kaylo prior to 1964 when all research
on Kaylo was terminated at Granville Two of our three available autoclaves
are in storage for lack of space
.
ard
Mr. J. H. Thomas
-3-
October 23 1967
At the moment we are attempting to zero in on the improved stress formulations to be poured after November 15 when a supply of 2399 becomes available and provide as much technical service to Berlin
corrosion
glass
as time
. and manpower will permit Our manpower situation is becoming critical The recruiting program for new people is batting zero As for additional
space we are working with Fred Swank and Ike Myers be required to provide the space we need
A 901 will probably
If you have the time available Thursday when you come to Granville like to have the opportunity of discussing this program with you
I would
RFS
R. F. Shannon
"
Be. J; E, Thomas, Toledo
1. 7. Shannon Cranvili
CDANETOVELOP DEVELOPMM ENT DEVE ELOPMN ENTDEVT ELOPMENT
October 1967
Pl Pfalfer sent me word last week you wanted to talk about the replacement
of asbestos program I attempted to contact you several times last
plus on Mond of athy is veak without mess As all of Monday Monday this veak without mess
yarns To FiberglaFibserglas Fiberglas
soated Fiberglas
PL Pfadfor Pfadfor asked Wong for oralmtim of getting
PL Pfadfor asked Bob Wong help
for soated a Fiberglas ef yarns Pfadfor Pfadfor asked Wong for help getting getting getting
send the results the yarns for us, wo will evaluate 4a Kayle sad
.
.
.
-
The epoxy coated yarns reported recently as being used to good advantage in cement coated coated yarns They recently stiff being to good advantage advantage
miniature fishing rods They are quite stiff about the dise
ing Mr. Potts FIX Division 3 They quite ir, Nabray.agreed Nabray.agreed to ay
ing Mr. Potts of FIX Division in New York to Rensselaer Polytechnic .
=e
Institute on Wednesday October 25 to
discuss the smoept aith Professor
r
TThhee prpogrramogprorgraammhdirected toward replacing asbestos in Lyle is complicated
at Berlin, (2) tAhnevenseteadsaftorreplaacindg dreiplatciingonreplaacinglasPbesltosanasbtestoscLapyaclitey aimts (c3o)mplpicraotecdlceonmpslicated
before expansion expansion expansion undertaken undertaken undertaken of Questions be anarred anared anarred include include
before under istunadek rte akn en anta o ber anarr red e includ de 2 do
if expand Berlin 901 now in Toledo er de to build a new plant and
if aarneotbhueilrd a new plant do determined determined de build build plant and process
or
process yet to be determined
.
os
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.
I
cannot
say
at
another
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pe
rainforcement
rainforcement
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:
rainforcement
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preferably
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preferably be
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susceesful
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tn
developing another;
of rainforcement preferably glass whiac s h be
adapted to the the of rainforcement pouring procese procese best adds I as project
st the nament are 50/50. In any ease, he problem won't be solved in woox
bal el.
7-3 fs
o
mae
oo
&
In which of used used our prepent proses is nother rula
which can be used in our prepent prosess is at the best 50/50 do we . also direct use of our effort toward a new process and if so what process At not contain contain toward toward new process insulatiwho at nthse
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Instead if the decision is to develop a product based on glass fibers I would recomende recomende werk on an inargane bonded glass fiber somposite
which on be produced in 4 mesta operation poss viaia b modl ifiy ed
Am
t " r prees operatin -
.
an
We must not forget the bonded aggregate type product Carrytemp is a bonded perlite reinforced with glass and asbestos fibers Kr Philip Carey
could solve their breakage problem Careytamp would become the best high
temperature product on the market I believe an would version of such
product containing 100 persent glass ruiaforgement would have a high prob-
abil containing i suct cesy s. 100 persent glass glass ruiaforgement ruiaforgement ruiaforgement have eting
canceled on us year after yuar in the past.
.
Now that I have given you a brief insight as to my thoughts as to where we go from here, I would like te insight as my thoughts to where
for asbestos Th efort should e hitting inte main nlys foi r v fie ber substitute for asbestos The effort should be directed mainly toward plass fibers de should not, however, aleee eur directed directed mainly ceramic fibers, which
exploratory exploratory available is the
time. We she feasibiliu ty inl itid ate
an exploratory program directed
ahesiding the feasibility of develop ~
ing a glass reinforced bonded aggregate or an inorgamle bondad high temperature
glass fiber product Multitemp via a different prosses
Your first thoughts to the above may be we are spreading our activity too
much We should instead deside on one program Under ordinary ciremstances
I would agree with the ides of concentrating program Under approach However vsust vsust recognise the fact that if we direct all our efforts toward finding
& substitute for asbeas ndtifens ot succews e cs ouf ldufil nd ourselves with two plants Berlin and the sev successful sucesful
requiring asbestos On the other hand if
looking fora substitute for asbestos but devte o dlevo elp op a bonded aggregate or high temperature glass fiber a la Multitemp product we & death to sentence Berlin the SD cylinder precess and the huge invest ment in the pan pouring process 1.80 process precess precess an the huge invest invest 10 in the pan revamp Berlin to 1.80 1.80 process
Waat are the chances of toahedosl suscene? I would gussstimate $0/50
reinforced replacing asbestos in aggregate product pouring process, percent percent fo a glr ass
reinforced bonded aggregate product and about 80 percent for a stop pressss Multitemp type product having a 30+ percent gross margin
re
need mampover and facilities is facilities the carry out any type of program we will need facial ndifatcii lie tis es At the moment I am down to two technicians
ond mampover mampover and facilities facilities the moment am down to en all research
are Laylstoorage terminated at Granville. Twe of our three available anodiaves are in storage for lack of specs
01 022 1469
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Mr. J. H. Thoms
-3-
|
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October 23 1967
bd moment we are poured after 15 improved d
The recruiting program for now
are
required
with Fredpeople andbetting Nyer
As for additional
additional
additional
:
required to provide the space we need
:
Like te have the oppertanity of dt fing this progres vith you.
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