Document 5DrBw5EegjaBK01vbOyO58RNe

UC-t4ft*4 \r IS UNION rCARBIDE INTERNAL CORRESPONDENCE UNION CARBIDE CHEMICALS COMFANY PLAINTIFF'S M ^u-S?v.. S Svcsvw'nZixs*:V".' = v 00755^;-: lOV-OOOS. 1=3 FOR MAR > 1962 To (Namo) Company Location Copy to Dr. C. K. Fink, TNY Mr. H. L. Harwell, NYO Mr. W. R. Johnson, 514 Dr. T. R. Miller, NYO Mr. C. D. Neil, TNY Mr. H. L. Robinson, 514 Mr. D. C. Blue, 511 Mr. J. W. Biddle, 511 Mr. D. W. Hess, 511 Mr. J. E. Hyre, 511 Dr. G. Magnus, 511 Mr. R. G. Massey, 511 Mr. A. E. Montagna, 511 Dr. F. P. Reding, 511 Mr. E. C. Stout, 511 Dr. W. J. Tapp (2), 511 Library ' Doto Originating DopK March 2, 1962 Research and Development Antwring lottor data Subfocf Report File No: 69H-S109 Gentlemen: In the recent report by W. C. Kuryla and D. G. Leis Fibrous Fillers in Flexible Urethane Foams February 23, 1962; tile No. 69H-S109, in the final paragraph of the first page, Dr. Tapp was quoted that "...the references to negate the patent ability...". Dr. Tapp has called to my attention that this implied the expression of a legal opinion which he is not qualified to provide. What was intended, in good faith, was to state that Dr. Tapp recommended that the prior art was such that it would be difficult if not impossible to distinguish the reinforced foam as a novel composition of matter over the published literature. For this reason the invention disclosure was not submitted to the Patent Department. Very truly yours, WCK/ras W. C. Kuryla STATUS REPORT Fanaal FIBROUS FILLERS IN FLEXIBLE URETHANE FOAMS FOR AUTHORS: W. C. Kuryld D. G. Leis, Group Leader dates February'23, 1962' " .... file no: 69H-S109 t Project No: 2560A SUMMARY Flexible and semi-flexible polyurethane hand-foams with fibrous fillers incorporated therein will support a greater load than control foams containing no fillers. The greatest increase of load-bearing (I. L.D.) in flexible foams was observed with fiber glass. In the future an attempt will be made to foam a polyol-fiber glass slurry with the Hennecke UB-52 machine when a pump suitable for pumping such a slurry can be located. DISCUSSION High load-bearing flexible polyurethane foam is of commercial importance since the foam is sold by board-foot and graded by the load-bearing ability. One way to achieve such a foam is to incorporate reinforcing fibers into the foamed polymer structure. The fibrous fillers were incorporated into the foam by first premixing into the polyol and then hand-foaming the polyol-fiber mixture in the usual manner. Fibers used in the present work include glass fiber, asbestos fiber, cotton I inters, and DYNEL (chopped) staple fiber. The greatest increase of load-bearing ability (I.L.D.) in flexible foams was observed with fiber glass. This result is in accord with the fact the strength-to-weight ratio for fiber glass is unequalled by any other material, provided the surface of the fiber has not been abraded (1). The data for the laboratory hand foams having fibrous fillers incorporated therein are presented in Table I. The literature gives some reference to the incorporation of fiber glass into prepolymer and polyester urethane systems (3), (4), (5) but an example of fiber glass into a "one-shot" flexible foam system seemed lacking. An invention disclosure (61-CD-15) was then written. A short time after the writing of this disclosure reference (2) was found. Dr. W. J. Tapp of this Department then reviewed all the references cited and decided that enough prior art was present in these references to negate the patentability of fiber glass in reinforced "one-shot" flexible foams. The invention disclosure was declared inactive, and not sent to the Patent Department. Research a>d Development Union Carbide Chemical* Company SOUTH CHARLESTON, WEST VIRGINIA 69H-S109 -2- It is strongly felt that flexible foam? having unusually high load-bearing properties could be made with a foam machine, provided a pump suitable for pumping a polyolfiber glass slurry can be found. The cost of fiber glass, as "milled" 1/4 in. fibers, is of the order of 40-45 cents per pound. Thus, the inclusion of a few parts fiber glass per 100 parts polyol in a flexible or semi-flexible foam formulation would not be economically out of the question. Such high load foams might find utility in packaging and other specialty applications. EXPERIMENTAL The fibrous filler was first premixed into the polyol and the polyolfiber mixture hand foamed using the formulation below. All foams were then oven cured at 140C for 15 minutes immediately after foaming. Formulation Polyol (NIAX triol LG-56) Silicone Oil L-520 Water Tetramethyl-l,3-butanediamine Tolylene diisocyanate Stannous octoate Fibrous filler 100 g. 1.0 g. 3.5 g. 0.10 g. 3% excess 0.30 g. Varied (Table 1) BIBLIOGRAPHY (1) Green, C. H., "Glass", Scientific American, 204, 92(1961). (2) News Item, Rubber World, 138, 417 (1958). (3) Moroni, R., German Patent 939,404, Feb. 23, 1956: Chem. Abs., 52, P13,303f(1958). ~ (4) United Aircraft Corp., British Patent 712,408, July 21, 1954: Chem. Abs., 49, P4443b (1955). -- (5) Velatex, N. V., Dutch Patent 70,960, October 15, 1952: Chem. Abs., 47, P5158b (1953). " NOTEBOOK REFERENCE: D-4333-47, 62, 67 LABORATORY ACCOUNT: 81717-06-3102 PERIOD: January 30, 1961 to August 8, 1961 Attachments: 1 Table S tiff flexible foam ---- 93 1.88 38.2 56.9 76.9 14.7 1.7 Good flexible foam 69H-S109 -3 - EE oo tio uoZ. E o 1o4- ll) a> o Eo .a M -Q Eo X *5 a) g o X a> E a> o a E O Q 4. Ut4>- if* t a> c Urn **- tiooS -Q 'x tCo a> <o 4> o toil tOil 4> .u0- 4) c:-- J3 X 4> W -D 4- <f>* X oaV 4> -O 4) 4. JQ X .a "x 4) -O -Q 'x jD X o X L*_ V 4) 'x 4) 4) _c -C tz _c V 4* tz IZ 4> t*-- a: -ooo O ? a> E too J <1) E o on "O o o O ? 4> E o i/i 1/1 TO3 >V cS "8 o O ~o o o o *DOO o ---- -- PHYSICAL PROPERTIES OF FIBER-CONTAINING FOAMS 200 -- 2 .1 1 .5 4 3 .1 2 .2 2 .9 3 .9 2 .9 2 .0 VX 4) 0 OJ_12 *5 o vp 0s- 01 x -* CN CO a U*. "D o o m 9 IN. xf O' CN CN O CN CN CN CN CN ! i 11 11 00 In 1 CN in 1 in i CN 1 Np O o CN in O Q _jCN in o 8 CN o 00 O fQ i -o a 01 -- c .2 c o ^ tO S' o in Xf rC m CO Ot N> O o o <> xf in o O'" m o -- IN o-- 4) -- <n CN in CO s 00 CO V CO n CO i 1 i 1 in - 1 1 s>* Fn CN 1 O' 1 in CO xt 1 CO o 1 in >n O' -- f m CO 1 CO CO 1 1 1 *o CN CO X 4- 4-- -- **c\ O' o CO >0 O' " O CO <D V) CN CN CN CN Q -> 1 r_ o CN <> 1 1 CN | CO 1 -- 1 1 a>> ctd) oo ai. P O' "* In -- O CO -- CN O' CN COO' 8 CM o o o in in o V-/ w om in k o in o om 1 .0 5 .0 'O e i0s) --3n o xj* xf x^ o \\\ 4 d) 4) Q. Q. r= o O) 4) O = <o/) = 0o = 0o O o o/) = 0o s 0o 4 1 o trt o c 0) Q. O Qo. JZ _E cU -Q o LZ C\ O) LO.) <D M LE LO.) <D M lE LOa) d) LE oc f-- z o uo> Loa> LD.> O' t-- 0) o M 4) _Q z lE LE m o c O *" c o LU z _l UJ z o o >- >- u uuUQQ _ CL . oE 7o -- CN CO UXJ m 'O CO O' -- CN 00 N" Asbestos, 1.0 Asbestos, 10.0  69H-S109 DISTRIBUTION Dr. C. K. Fink, TNY Mr. H. L. Harwell, NYO Mr. W. R. Johnson, 514 Dr. T. R. Miller, NYO Mr. C. D. Neil, TNY Mr. H. L. Robinson, 514 Mr. D. C. Blue Mr. J. W. Biddle Mr. D. W. Hess Mr. J. E. Hyre Dr. G. Magnus Mr. R. G. Massey Mr. A. E. Montagna Dr. F. P. Reding Mr. E. C. Stout Dr. W. J. Tapp (2) Library INDEX LIST Polyurethane foam Fibrous fillers Fiberglas Cotton 1 inters DYNEL Asbestos