Document LK5XGRnaRkZnMZnJm163RQZ3Q

FILE NAME Corning OC DATE 1967 Oct 23 DOC OC276 DOCUMENT DESCRIPTION Memo - Kaylo Product Development H. EXHIBIT Mr. J. H. Thomas Toledo 7 R. F. Shannon Granvili KAYLO PRODUCT DEVELOPMENT ; | October 23. 1967 Mr. R. J. McEvoy Granville - week you replacement Pi Pfeifer sent me word last wanted to talk about the of asbestos program I attempted to contact you several times last plus on Monday of this week without success As you know I was in all of last week working on plant process problems week Berlin To follow on your request move promptly on the evaluation of coated Fiberglas yarns Pl for Pfeifer asked Bob Wong for help in opexy getting us a supply of such yarns for our evaluation in Kaylo As soon the Chemistry Chemistry Lab produces the yarns for us we will avaluats in Kayle anads cement are in reality reported reported recently coated with epoxy resin advantage The epoxy coated yarns in reported recently as being used to good advantage discuss the to the miniature fishing rods They are quite stiff about the size of picks and about 1-1 to 3 inches long Mr. Molvoy agreed tooth ing Mr. Potts of FIN Division in New York to Rensselaer my accompany- Institute on Wednesday October 25 to Polytechnie Professor mink inventor . concept alth Professor _ a The program directed toward replacing asbestos in Kaylo is by 1 the huge investment we have in the SID cylinder complicated at Berlin 2 the need for additional plant capacity pan pouring procERE and 3 problems of which must be answered as to type process to use in the new facili before expansion is undertaken Questions be we a new plant expand Berlnienw plant if we build a 901 now in Toledo or do do we install the or another process yet to be determined to answered include (1) do we build and (2) SID cylinder pan pouring process I cannot say at the moment with any assurance we will be successful in developing another type of reinforcement preferably glass which be adapted to the STD gylinder pan pouring process at the moment can The best odds I can project are 50/50 In any case the problem won't be solved in week will or month In fact we be lucky carry a ~ to the program a stage a to plant trial ; .. after year's effort 4 w:efs eete ow MB OT tl he ge ae. . . - re In view of the fact the probability of finding another which can be used in our reinforceme . also direct some of present process our effort is at the best 50/50 do we toward a new process and if so what process At the moment there are no high temperature insulations the market which do not contain at least some asbestos To on the best of our be no The Miltitamp Miltitamp concept of post impregnating a prebonded wasiill conceived It does not lend itself to product adequate profit margins 01 022 1468 { P el ee ees Oe ee Oe cate eee Se A 0 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 - . - on We must not forget the bonded aggregate type product Careytemp is bonded perlite reinforced with glass and asbestos fibers If Philip Carey problem could solve their breakage problem temperature product on the Carsytemp would become the best high I believe an OCF version of such a product containing 100 percent glass reinforcement would have a high prob- ability 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 alose 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 develop ing 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 tos much We should instead decide on one program Under ordinary circumstances I would agree with the idea of concentrating on one approach However ve 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 for a substitute for asbestos but start to develop a bonded aggregate or high temperature glass fiber a la Multitemp product we are giving a death sentence to Berlin the SID cylinder process and the huge investment in the pan pouring process A.so we will face an outlay of 6 to 10 million 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 reinforced bonded aggregate product and about 80 percent for a step process Multitemp type product having a 30+ percent gross margin Pore What really bothers me is timing To caour t ar ny ty ype of progwr e a wim ll need manpower and facilities At the 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 01 022 1469 becomes available and provide as much technical service to Berlin as time and manpower will permit Our manpower situation is becoming critical 4 The recruiting program for new people is batting sero for additional ee space we are working with Fred Swank and Ike Myers A 901 will probably be required to provide the space we need re ~ Ot If you have the time available Thursday when you come to Granville I would like to have the opportunity of discus ing discussing this program with you b~ 4 b RFS eo b. - -4 ee oe an ee ee eLp a . 01 C22 1470