Document 65y7ZLREZOXXx0pVVKM1mvO9d

Wood Panel by Surfacing Dear Mr. Rawlings: / / At the recommendation of Mr. W. H. Kohler, 1 am forwarding to you a letter and an information bulletin sent to me by Mr. R. P. Villeneuve of North Bend, Oregon. The information bulletin describes a patent for improving pressed-wood panel by surfacing with a compound of thermosetting resin and asbesti- form material, Mr. Villeneuve is inquiring as to the possible interest of Union Carbide in this process. j Mr. Villeneuve also sent me several samples of plywood panels which have been produced and tested under a variety of conditions and temperatures. If you feel that these samples would be of use in determining Union Carbide's possible interest in this process, I will gladly send them to you. If you have no interest in the samples, I will return them to Mr. Villeneuve, as he requested. / Will you please communicate directly with Mr. Villeneuve. If there is anything that I can do to assist you with this, please call on me. / Very truly yours, / JEM:rs Enc. /SyZ. Morgan [/ f' RECEIVED JUL 2 3 1971 UCC 004691 Roger Paul Villeneuve Post Office Box 562 North Bend, Oregon 97459 July 9, 1971 Jim Morgan Union Carbide Exploration Corporation 751 Ryland Street Reno, Nevada 89502 . Dear Jim: Approximately two years ago I brought to your attention a ply board made from asbestos product. Please find under separate cover some of that board. Additional tests are being carried on on the board and so far the board can resist 3000 degree heat. The boards can be made in attractive different colors and patterns. After your company looks at the board, might it be possible to return the samples to me. The owner of the board feels that a major timber company such as Weyerhaeuser Company or Georgia Pacific could produce the board jointly with Union Carbide. Union Carbide could supply the asbestos and chemical; the timber company could supply the plant facility and wood. If your company becomes interested in this matter the owner is very willing to come to an understanding with Union Carbide. Hoping to hear from you at your earliest convenience, I remain Sincerely yours, ^ . Roger Paul Villeneuve RPV:pl UCC 004692 L'lvOiL'IATXOli liUhLi.LiXXij ASbhSfOS PaGltfCTo, Ihva, 3677 Pino a tract. North Lend, Oregon //hy) January 1, rjyx TrCa PATim-T - ' The principal property of this corporation is a patent (par, no. bp7o97) developed by L alloy Follows and . H. Hannon of forth hand, Oregon. This patent covers ran material and processes for inpio /rag a pressed--aood panel (con bo plyuood, fiberboard, particle board, etc.) by surfacing one or mare siaao ulth layers (1/d-Inch ~ tbicn or more) of a compound consisting of a thermosetting rosin ' ipnonol-fomaldohyde, melamine-formaldehyde, etc.) and trouolite asbestos. The trenolito is ..lined vith a thermo sot ting plastic binder at a ratio of mineral fiber (tremolito) to 10,., resin. It is sprema .. tlio panel core and placed in a'hot press, where, under the infj.uone^ of boat and pressure, tho rosin is "set11 one cured. Tho resulthv, composite panel consists of a prossed-wood coro, sandwiched u laminates of af.boctos-b.tse plastic material, fills .Material lie (on. uo bent vithout warping or cracking), it can bo drilled without chipping. it has a liard smooth resinous finish th,..i useful as a for.*, panel for reinforced Conors to fills panel Is water rosistrait, rot-resistant, tsrnito-rosist..nt and fire-rosicLent. l/ith a plywood core, the panel has great struc tural strength that constitutes a useful material for tho building a x; construction industry. Iho panel can be easily savied or worked with ordinary hand tools or portable oloctric tools. This panel can be constructed with an ordinary plywood typo hot arose. Aviy manufacturing plant possessing such a hot press can nanu fac euro this panel with very- little capital investment. basic raw . tutorials arc utilised in its manufacture which are .1 a. to cosnon and in natural abundance; Tromolite asbestos and them kn; - plastic material, principally phenol-formaldehyde. These .'-Is cm bo produced at a of cost due to the fact tint the _ materials ere readily available and in abundant supply. Furthsr ; . ` enl;r machinery - a IS.at readily . r0r.11'j invention ,is based on the wull-.miown principal that ... .`.me t osy mineral f11lord t 41 k ifc'.l L 0 I ...A .0 ii of tno i T... Plastic materials ere organic compounds Inerting fillers or reinforcing mineral h fX J. i .J have long b v.kv ii'iiiv*os. In roc; jars numerous applications have boon .moo o.1. ^EC'O uPcEeS;<O UCC 004693 thu unusual firc-rosictivo qualities of ashes tos-baac-i.in.iiOiic a.sin lauiiintcs, coxiGeructod oi long-fiber ehrysotilu 'asbestos I'Glt',-im..ro iic'-twa and pi'es sure-molded T..*i oh phenolic rosin. a superior heat- resasuint product is tuus obtained, union has round applications as no so cones and heat snielda ior the vary hi^h temperatures oucemUre1 in space alight. '..hen a molded sample is subjected to the flu.ie oi" ' bio'..torch i or a short period of time, tho heat is concentrated in a small area. Thermal aogradation sots in at t'ao surface, but because of the poor boat conductivity oi tho Material, tiio extant oi* degra dation does not go yuch below the surface. A1 though tiio rosin bclav' tiio surface. shows siwns of carbonstion, tho structui'al unity oi the sample remains intact. This carbonaceous surface insulates the inner structure from high tomporaturos arid decreases the rate of doc^mposico lihon the entire sample is subjected to temperatures above 2012-* F over a Iona period of time, the Material will eventually lose its structure unity, in this material both the rosin and the fiber contribute'to the heat resistance of the laminate. The use of Ion-'' fiber chrysotilo asbestos in a nass-produccu composite panel would be prohibitively expensive. Xt has U.g ... felt that only chrysotilo asbestos would fill this roll since if,, variety of mineral fiber tin great mechanical strength (tan ti xr strength of nylon;, whereas other varietiesthough inox-nvxn . , to bo veal and brittle. ;1.. c Mr. Follows and Mr.'Mcnnon, in their experiments, have f- solution to this problem bp- tiio use of a pros sou '.rood struct i as a core to five the required strueturai .strength to cho c: board. In addition, it was found that at ui.yi temperatures 600 F - the rosin is not' completely nostro, ea, but is cojrs... - a carbonaceous material which in itself acts as a binder i<-<_ .. asbestos fibers. On heating tiio fibers become coated and into .. I into a solid mass. Thus tho mechanical bond of the fibers is supplemented by tho chemical bond of tho phenolic resin, producing a now* and superior bond. Uhen thermal degradation sots in, the rosin is converted to a carbonaceous type binder with unusually high heat resistance. Tho residue nay, in effect, bo considered a "sxciotor.11 of tho rosin moloculo. It has very little strength in itself, but; as. ' coating over tiio fibers it adds additional bonding-strength proper el to the intorti/ined fibers. Thus even a low-strength asboctiform miner ach as tremolite can. be compounded with phenolic rosin to xorn a good uoat shield for otherwise combustible pressed-wsod panels. This cun bo done at a price '.tall within the reach of tho buildinj-coustrac tion i.dustry due to the natural abundance of the materials used. Many previous applications of asbostos-bssc phenolic-rosin Mato id. a ' ed a larger proportion of rosin than is used under our patent (Up) in order to obtain a hard, smooth, resinous surface, fhor-al doc position of tho resin in fire tests caused production of snoxo and ^ c gases. Xt is our belief that tho reduction in resin to.Up of . e total uoight of the surface . . x;e undosireabio byproducts* laminate results in a In applications where dsuimrfaincuetioL#n J. of , L' - *' is uosiroablo, it has*boon found that a thin surface dressing of fix. round tremolite, nixod with 3^ resin, results in a superior sur.facr finish, if color is desired in th- suriaco iriiish, cle 1 formaldehyde resin with odor pig. von os cm 00 used xn In- - lire: ssiu... UCC 004694 Processes to date for flat lo-proofinj lunger and ply. ra^iL y l: I ire-proofing paint, tilled produces a contiucscunt cdur^ -m -m- *- mm ~ ) . . p ^ -- -- mm * -- w - . -r -w.. w - w wj. * -- J. J. 4. j. 'jAiCft^ 21, ^ or pros sure- inprog'n a tin-.- -./.Ltd soluble salts, > theso processes a.1l1l have one uoobness; they are subject to rapid dotorisration by voathoring and'are not approved foe locutions subject to uoIclare. Our pro cos sos result In tho construction cl composite pa.no Is './hied aro vafcerprooi' us veil as firn-rosistivo. Thus they have special application to functions in locations subject to ...oiaturo .end v/oatfiaring. it is our boliaf that they have on inportant future in tho construction of lev cost firo-rasistivc buildings and donas. Vie also have plans Tor developing pnuol boards vhich are primarily docoratlvo oral only secondarily xlnso-rasistivo in design, Vlith the * lisa of tore fcur eel ferns in the dot press on surface lmlnatos up to 1/4-inch tilled, usin'; clear rosin In r.oro abundant quantities and coloring pip, louts, a co.sposifca panel nay bo cons true tod to rose able, brief:, tile, etc.. The possibilities for devolopucnt aro nusevous / and i/iil ;,o pursued. In addition, elan to develop a lou-oost panel that would substitute for ordinary plasterboara as an interior sheathing. T'-V, type panel v/ould probably have one or noro layers of paper d . .. . a core, with outer laailriutos deillar to tine-.. doscribod above, s that one side v/ould bo finished in vtdito. bach a panel v/oula .. lightv;clgdb, could bo produced at a uederato price, and v/oul. -.v firo-rosistivo qualities far superior to plaster or gypsa.i ba , It could be sv./ucl v;itd an ordinary sdillsar without. orodr.ei.i . .. dust. Joints Co aid be taped and patched In a a-urnor shell- r :' present practices v/ith calcaroous material. It is tho intention of this firn not to go into tho business5 but to act as a franchising firu, allowing qualified ...unufacturors to produce tho so panol boards for a basic consideration of O2i>,030 plus a royalty bused upon tho quantity of tho board produced. Tho also of tin royalty hue not yet boon do torained. Since^our patent hue boon granted in the United Stales, this fir.n ins applied for patents In Canada end Japan. Our activities In this field will be Lutornational in scope, and va will undoubtedly apply for patents in .'dibicnal countries. K j *L* rjJ\ :v\ ru:.,v.l ju/iri-u U> -- Larger franodise -holderr: will probably vrish to control all stages on umnlaetnying, iron the .Mining or quarrying of treuolito to the -lining of resins, dovuvor, suallo? companies v/ill probably want so.ee nsr.issauco, in the for. i of procuration of rnv. uat-eria.a.'is as TV i 11 as de ni a - ting tho fxi-isdod products. Cno product v.c dbo fplla:un: tibj'ov<s prooddu1 ce a dry uizctuvo of tro-volitu and r^siu, puedaged^ ini \v/ooiijjiivvoedd u'luniXitt*s. , so _.ut dicjivtouts of one pucdaje v/iil cover one sidei oovr a p/:euaejoll bboo. .rd. :u ..I.lu: 0---^ -lea rosln-ii.iprojuatod trc./.olite f(eellthsa oo Ar : 0 L4...'a. j ,*:i,LCii cm o: dondlod li t saoo ioarmor us vouoor. by r/ius on of tl capabilities, there vMll ------n--o----r------------ ' m ' 1 .' .if ...teed.....,.o.l.;^17) ;:a- qualified nanuiV.uturor, regardless of si to, to lari . uU- UCC 004695 , '.V* J..,, -vi '.'UC [ -1Z" i j C.J O 0 ; Imsinos:;, i. '. ! , i k .bo r^r toSj ^ iii so^-iiO lno 1*0 ..^i 7 cr v stuff of toed. tho actual .a;::; far !v . a p; < 1` n C`J CS U -L* * i. tin u-L*0* demur! for this or vie;3 increases. in the cil r of iijr eh .0 and era;;f: tan ta.l !;c /: `o, a ssjull plm t for Cclii 00 a aUit-L j.i tha To fabricate a snail saftplo of such a oc..;po&ico panel tho invantor* g laboratory is a mttsr of little difficulty. dba; t j bo done is to dovolop mss production oooA.r.i^uus, suits. ui!.e by are vi ...am'ix induo , so taut t/ieev pz'oof'.uts orai ue *.ictjUii`ae\u.:r,..._+ cviftly, irltli case 3 and at no treat expense. lu audition, vc vixl mat l-.j a,.vo our various panels thoroughly touted end carry the approval of recoyralmu. to stint laboratories, suck as bnuor ari .,<... a1 jji .00 rntos, wo * . ' Aid h/yia \LAUj - ttUoru arc twiy accoptuble processes for -imfnoturim; . r JO 1 t'.i'J.J.ii . ); tGiiOj* LC Olii.iO-s.1 JC*:-iO SO 4* t cm. do: carry w inventory u_ .; .. var. JL huiwrad awrorcat w ,il .. c. , ava "variisaor/1 of this uutorial. Vi r h vo a laotod as. w . _ . uovrsor in SoJr;C0r,.a ,,sivt oo.i-.oui:o 1 .' ra / 1..aueri...... 3 i Cho.iicaiO; .me. 21tm corporation ha-: v.c. . ^waul comb.!,: U,. dais wry tocdiiicrl field, owe vo hnv . caya, a* ucra,i;\j va........ W.o Lu mV Idavie froi lu^ uf lioiohold dbtmici s. binco other Varieties of asbestos alej..c. .ounjo lire tie a.-.-Ui. miswal field, the local production of troaolim -.rill have to ..a ono-juraped. `inis ixm. has node a 00arch of a tliroo state ora., (, iaaho, hauhlu^tou and oreyon), and mo have found plentiful supplies available B, i'll farm states vi bh only a .uaricoc for tho i-iatoriai van tiny i-o da. ; a i.oirood a c;:.oaltlna onyinoor to oui' staff vfj.o viill purum . .. a jvj ic.i t o t.f i_^u aJ. tj xc1 a.11 spurco^j oa Lt'* irx.i.'jvj t.ra'..o..^>r is a lov-cost i-.Bioral, trmo^ortatiou coses oatar very ala mtiy ..;.r.to t.. s.;l coot of the mtorial. The develop.:.'`at of muarmis ioc-1 res.-, of tills .mt-minl vill hoIp to mduco aba total eo~;t. it Is o' .i.oyr cast vo .r.., I'ovslo'v 0 vholo uov ::dn uy industry, baser on ,.r ;t.:;ictio*i .'sid nolLisation of this vary ..irouisivy asbostif-..r U it is no t our present intentto enter dirocul d 1 A `j.i .J.nv'.y; v..r:u o`,jx_L tdhr.ami.. i.n'i .sji-Tni-oJ ssB ,^ in Ji'w ", JvL i.uj ..1. iO aiiut'j oKaUiv^Ooll"v/.os,# if uocit bo,^ iii uit.jv to provlc-.c ov.r vj'1 -* ; .-LvGjTv ...-. Ol* m _L --- i -- 0 __t La L Ux buill l,\c`.X j -.?fc i,Oc\inOiL^l!-)"L|J. C r [j u r a.; above domri. .',i /o iiatoriul is offoren to tb-o p.ubiic a.s imo.*...~ a '-.`.oii a.ly a,00at Ou. t r; corporation ai.u it:; Ol'.iIC 0S n aviu aS l: J '/ f; b.. v^.iSa'isi.1 as ,r\ oiler so,l1 sacurit Los. D. A. 0oceu daca?t_ry of ;.' 1.1.'. UCC 004696