Document NEjmkMvOVkEywaov25pO1grzy
FILE NAME: Engelhard (ENG)
DATE: 1968 Nov 26
DOC#: ENG102
DOCUMENT DESCRIPTION: Engelhard Report on Development of Non-Asbestos Heater Housing for Ford Motor Co.
- ".
,-s .- . .. :
'-v,~^>V i-'-.. y .-.} . Wf*'v.*^tWl DEPARTMENT
Document No.
*i?iir: v
.,r.r,.,,' .y.^.:^,,'1. _ *ji*
" Dwiv"*is"i4on
Chemicals Corporation
iv;:v ,.*' -.- i.
j.xf-gye^H5fc. KH&L gREPORT
i^ .'.^ r r
FKSilX HEATER HOUSING FORMULATI ON
I 503371
9 Reported by J- C. N e a s e i p ^ ^ O ^
" T /
Approved by
f f ic d m
L -.
I
r
.r. Date
November 26, 1966
* $ a i E S m flRMIX HEATER HOUSING FORMULATION m -' ' ' ""
IfciujpDund without asbestos that 4$&! the present Ford formula in
cost*
K s :;' SlliM-. H ' :
v 1-
i0, experiencing severe bulk handling problems
manufacture of heater housings from
' '^Caipcund. In an effort to design an alter-
!* ' LAte these problems, the following five
^fere
^fcolaed and tested in the Menlo lab and
ifeyw`tested by Ford Bt the Sheldon Road
^ W C a O O e fownul*.
PQP/CbC03 asbestos formula,
:fdnigjijL* contahing ASP hOOP and CeCCs
jial'.forffiyCU containing ASP 600 end CaCQgtdl' p ^ s0 \& containing Attaclay and Cafu^.
^ower eoet for the experiffisni^njjformulations compared vithwie present Ford
tino.-ibiitween Menlo and Ford on. flexural strength ;i#'(,b^f$airly poor correlation un flexural
- .* J**' * _^^C^^srmulation yields t.he highest flexural
the Attaclay, ASP 600, old Ford, and formula^ in decending order. Only the present ilh aOhj|iatently meets the Fori specification for
jfrfcy. ]
Frari :dpraula in within the specification for ^ v i S i - s S ' . * ^ 'nsodulus whereas all other formulas yield higher
" ieutTf-specifleation) modulus values.
fa d u a n o
CT, GAHa, Max D&vgy. AJR.
PLAINTIFF'S E X H IB IT -
ss / 7
iLLLZl
BASF01S39
., M & C 'Research Report fro. 5050-35 Summary gofl't;
Page 2
5. All of the formulations except the ittacJsy and the old
Ford formulas meet the Izod impact requirement 6. H. M. hardness, Rarcol hardness and specific gravity are
equivalent for all the formulations
RBCCtMMEMPAgiORS It la recommended that all formulations he presented to Jim Simmons
of Ford. Jim is equipped to make 200 lb, premix hatches and he should he encouraged to evaluate formulas 172h-30-2 (Attaolay) and 172k-30-3 (ASP600) on this scale.
It 1b further recommended that every effort he made to insure a maximum of 1.0$ F. 14. Attaolay, especially if a Bmall quantity is shipped to Ford for evaluation.
..ijtroQDUGTIQK .. '.................... ... ......
Until the labor stride in the kaolin industry during 1965, Ford
Kotor Co. purchased large quantities of bagged ASPkOOF for use in a polyester reain premix formulation to product heater housings for automobiles and trucks. Ford reformulated to an asbestos and calcium carbonate system when the ASPlfOO
was not available during the 1965 kaolin work stoppage*
Recently, however, Ford relocated to a molding plant that i6 designed as a model plant for Materials handling. As a result, all fillers (asbestos, cal cium carbonate) and reiniggeement {sisal fiber) are now received in hulk quantities and are handled in bulk||jaeilitiee within the plant. Sinee the switch to hulk handling, the new plant has been continually plagued with prob-SSms in handling the asbestos. The system plugs frequently and requires constant "poling" and
attention by an extra operator and the problem has become virtually intolerable.
PADUANO
C O N F ID E N T IA L
BASF01S40
Mk C Eeport Ko. 5050-35
Page 3
As a result? JJLm Siasaonc of Ford requested that Engelhard attempt
to design an alternate formulation using clay and calcium carbonate to
alleviate the handling problem with asbestos. It is also suspected that
Ford may be concerned about the carcinogenic effect of asbestos that has
been recently reported.
It vaa requested by sales that various ratios of ASP l00p, ASP 600,
and Attaclay in combination with Snowflake (chemcarb 82) Calcium Carbonate
be investigated in modifications of the Ford formulation. Flexural
strength, laod impact and cost were lisjtetB as tl a
iarportant parameters.
Ford agreed to do the impact testing since our Plastics Lab is not equipped
to make these determinations.
..EXPBRPAL..,&...])ISCqBSIOM
... ..............
She present Ford premia: formula (l) is shown in Table I on the
following page, but it was modified (2) slightly for simplification on the
recoamegiatioh of Jim Sirsmuns of Ford. Formula (3 ) in Table I is the
proposed starting point for this evaluation.
PADUANO
C O N F ID E N T IA L
BASF01S
M i l C Report No. 5050-35
Page ^
TABLE I Formulations
FORMULA Identification Ingredients, % Polye ster Hijsin Snowflaiic 7 T 1? Asbestos Sisal ASP hOO P
1 Ford
29.00
36.27
a . 97 10.01
2 Modified Ford
30 37 3 10
3 Engelhar*
29 12
10
ZJlnc Stearate
l.ftL
Benzoyl Peroxide.... .............. O.V*
Black Iron oxide Total
0.51
100,01
(1)
to
...........(2) ......
(2)
(3)
(3)
100
100
(1) 1.5$ added
formula vt.
(2) 1.5$ added on total resin irfc.
(3) 0.5$ added on total formula vt.
Formulations 2 and 3 Efere mixed in the Read Standard Sigma Blade Mixer
according to the following procedure;
1. Add resin, zinc stearate, hiecT3iron oxide, and benzoyl peroxide
and mix until homogenous.
2. Add the fillers slowly and mix until the hatch is wet.
3. After the fillers are wet-out completely, slowly add the eisal
fibers and stop the mixer.
k. Remove the compound and scrape the walls free of xmdispersed
ingredients.
PADUANO
CONFIDENTIAL
BASF01542
7 K & fr Report Mo. 5050-35
Page 5
' ",,Z-JL
5 Return the compound to the mixer and mix until a hontogeniouB compound is obtained.
6. Remove the compound, and place it in a polyethylene hag. The compounds were then extruded one pass under vacuum in the pilot plant pieton extruder using a 1 inch die. Ifce extrusion process serves to remove air and to provide easy-to-handle chargee for molding. Approximately 480 grams (approx. 10$ excess) of extruded "rope" was placed in the press and compression molded for 5 minutes at 250PF. The cured panels* 12l,xl2,?ji0.120"j were trimmed and 8 flexural strength samples Vere cut from the center of the panel parallel to the direction of molding. Flexural strength apd flexural modulus were determined according to standard A8JM procedures. Formulation 3 was slightly stiff after mixing and the molded paa^Heontained a number of voids. This compound was reformulated to EheBI
desired consistency and the results are shown in Table II as formulation 1724-30-5* The modified Ford control formula is also shown in Table II
as formulation 1724-30-1.
After several trial compounds* successful formulations containing
ASP 600 and Attacluy were produced aa shown in Table II and Identified as 1724-30-3 and 1724*30-2 respectively. la addition* the old Ford formula (1734-30-4) used before 1965 was included in this evaluation since Jim Simmons said that a Email amount of asbestos might be eegaidered if there was no other means to meet the physical property specifications.
PADUANO
C O N F ID E N T IA L
BASF0'
TADLE II PHYSICAL PROPERTIES 0? BAKELS SEHT TO FORD
F-o-r-mu-l-a-t-i-o-n--1-72-4 -
Ingredients, #
Cost, $/lb. (1)
Plaskon 9520 Chemcart 22 J-M 7T15 A sbestos Sisal ASP 400P ASP 600 Attsclay
0,1800
0 .0 1 3 9
0.0280
0.2600
0.0189 0.0206 0.0167
Total
R tearato -ii* Blad Iron Oxide, B o n z ^ rl peroxide P a a te ( 5 0 ^ ) ,
30-1
30-2
30
30
37
45
23
10
10
--
HP*"
15
l60
L00
1 . ..
0.5
1 .5
30-3
30 18 10 42
-- 100
30-4
30-5
30
12 5
10 43
--
~ 153
29 15
10
46
100
s.
Cost, $/lt. W
Calculated on total formula weight Calculated on total resin weight
0.0915
0.0888
0.0912
0.0912 0.0912
Flexural Strength, psi Flexural Modulus, psi XlO"*
MBELO TEST DATA.
7290
13*0
6230
11.5
5510
11.6
5200
5570 ,
U.3 11.6
DIrection(3) FORD TEST DATA
Flexural Strength, psi
{6500 psi Min.)
_
F lexu ral Modulus, psi X 1 '
C7.5-13-0 psi X10~5)
Isod Impact, ft.lh./in.
(1.8 Mitt.)
Rm Hardness (45-90)
B&reol Hardness (40-70)
Specific Gravity (1,55-1-85)
7380 6790
13.0 12.8 2.0 2,6 54-65 38-42 1.78
6500 5770
14.5 13.6 a.i 3 55-69 44-46 l.?8
4690
5990 13.0 15.4
2.1
2.0 54-67 45-51
1.80
13,1
2.0
1.3 50-65 44-50
1.78
4550 5360
l4,6
14.5 1.8 3.a 53-65 48-50 1-78
(1) Cost figures shown here are the delivered cost to the Sheldon Road Ford plant for each ingredient.
( 2) Formulation coat does not include sine stearate, iron
oxide and 'benzoyl peroxide since these are the same for
all formulations.
Samples "A" cut 90 to samples "B"
PADUANO
C O N F ID E N T IA L
BASF01544
yeQ^fSt
, XAELEX
2 im
PHYSICAL gROPER'TXEB OF PANELS SENT TO FORD
Formulation 1724-
30-1
'30-2
Itusradients. 1
eost.S/lh.W
Haakon 9520 Cheacarb 22 . J-M 7X15 Asbestos Sisal ASP 400P ASP 600 Attaclay
0.1800 0.0139 0.0280*' 0.2600 0,0189 0,0206 0.0167 Xotal
30 '
30
37
45
23
d
10
10
m
m
eu
--2--
IS
100
200
Zinc Stearate ,7**
1,5
Black Iron Oxide ,3*
0.5
1 benzoyl Peroxide laste (507.) ,%** 1,5
30-3 ' 38-4
30-5
30 1$ 10 * 42
100
30
29
12
15
'.5
4-
10
10
43
'46
' V
m
M
m
100
100
-- 71 --*
--
Cost, $/lb.<2>
Calculated on total formula weight Calculated on total resin weight
0.0915 ` 0.0888
O.Om
0.0912
0.0890..
Flexural Strength, pel , Flexural Modulus, pal XlCT5
MENLO TEST HATA
.7290 13,0
6230 11,5
5510
5200
11.6 , 11.3
5570
11.6
FORD TEST DATA
irectlo^^
Flexural Strength, psi
A 7380
(6500. psi Kin.)
5 B 6790
Flexural Modulus, psi X10I 5 A
13.0
(7.5*13.0 pal H O "5)
B
12.8
Izod Impact, ft.lh./In.
A
2.0
(1.8 Min.) RK Hardness (45-90)
B
2.6
54-65
Barcol Hardness (40-70)
38-42
85)
1.7B
*Mr--f*
6500 5770
14.5 13,6
2.1 l.l 55-69 44-46 1.76
4690 5990
13.0 15.4 2.1 2.0 54-67 45-51 1.80
sSrrts *rr 5780 4990
13.9 13,1 2,0 1.3 30-65 44-50 1.78
e"f#f jr
4500 S360 * 14.6
14.5 1.8 3.2
53-65 48*50
1.78
(1) Cost figures shown here are the delivered cost to the Sheldon Hoad Ford plant for each ingredient.
(2) Formulation cost does not Include sine stearate, iron oxide and benxoyl peroxide since these axe the same far all formulations.
( J ) S a n ^ U ^ ft" flu*-
"8 "
PADUANO
C O N F ID E N T IA L
BASFG154
'M & C Report Ho, 5050-35
Page T
and the old Ford formula, 1724-30-4.
The R. M- and Barcol hardneaa values and the specific gravity
of the experimental compounds are veil within the Ford specifiEhtian,
The older Ford formulation, 1724-30-4, containing ASP 400P
fares rather poorly in this evaluation. It is apparent tlijgt Ford has
increased the specifications 'for flexural strength J|Ijnce'the change to the
present formula was made.
fact is also verified "by work done in MCP
report 5050-24 (Aug, 1964) when Ford reported that the average flexural
strength was 5200 psi.
Without knowing the formulations of the five teat panels, Jim
Simmons reported to John Dihecj^Jof the A.E. Fleming Co. that he was in
terested enough to further investigate 1724-30-1, 1724-30-2, and 1724-30-3.
However,Jimauspected thatgEgJof these three va6 hi present formula Binee he had teen told that it was included for comparison purposes,
COHOIAIBIOffS
Compared to the present(jjord formula, the experimental formulas
containing ASP 4OP, ASP 600, and Attaday in various combinations with
Cherocarb 22 and asbestos show:
1. Lower flexural strength
2. Higher flexural modulus
3. Equivalent Izod impact with the possible cs^jeption of those
formulations containing Attaday and ASP 400P.
4. Equivalent R. M. hardness, Bared hardness, and specific
gravity.
5. Slightly lower cost.
PADUANO
CONFIDENTIAL
BASF01S47
I - * M fe C Report Ho. 5050-35
Peg 8
FUTURE WORK Mo future work is proposed unless information returned "by Ford
Kotor Co. ihdieatas that further investigations should be made.
PADUANO
CONFIDENTIAL
BASF01S4