Document YM9bgr6D20vd4Y3Ow432LONk

FILE NAME Corning OC DATE 1967 Oct 23 DOC OC033 DOCUMENT DESCRIPTION Report - Kaylo Product Development Mr. 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 for us Fiberglas yarns Pi Pfeifer asked Bob Wong for help a supply of such yarns for our evaluation in Kaylo in getting 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 rooth picks and about 1-1 to 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 insulations process At market which the moment there are no do not contain at least high some temperature asbestos To the 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 be no The Multitemp concept of post impregnating a prebonded product was ill conceived It does not lend itself to adequate profit margins | PLAINTIFF'S EXHIBIT 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 following 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 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 Also 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 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 . Mr. J. H. Thomas -3- October 23 1967 At the moment we are attempting to zero in on the improved stress corrosion formulations to be poured after November 15 when a supply of 2399 glass becomes available and provide as much technical service to Berlin 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 A 901 will probably be required to provide the space we need 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 [ a Cc et TT y~ Sr. Ji, Thomas, Toledo 3. 7, Shannon, ceumitie KANTO PRODUCT DEVELOPMENT Octeber 23, 1967 ; week wanted to talk about the replacement Pi Pfeifer sent me vard last of asbestos program I attempted to contact you several times plus on Mond ofathy is veek without success As all of Monday week working on in-plant process probleme. last on promptly To follow your request to move on help scated Fiberglas yarns PL Pfadfer asked Bob Wong for for us a supply ef sueb yarns for our Wong in Kayle send the results the yarns for us, we vill svaleate ia Kayle and yarns reported reported The epoxy cocted in miniature cocted fishing yarns miniature fishing rods recently good advantage They recently stiff being to good advantage advantage They are quite stiff about the dise Ricks and about rods to 3 inahes New Mr, Rensselaer Rensselaer dise xy Polytechnie ing Mr. Potta of 18M Divisiin oNenw York to Rensselaer Polytechnie Institute on Wednesday October 25 to discuss the eqspt Professor with Professor .nt .tmata .tmata .tmata - 8 e- .e moe - < . fo awe TThhee prpogrramogprorgraammbdiretctoedwatorwadrd replacing replacing replacing replacing asbestos in Kayle asbestos asbestos Kayle is complicated at Berlin, (2) the neefd or sdtitional plant aspacai ndt(y 3) before expansion expansion expansion undertaken undertaken undertaken of Question to use da the new Laaili before under istunadek rte akn en Question to be answered include . ^'s we expansion expansion is undertaken undertaken Question Question Question ve answered o answered include include or another another a process yet be determined determined ? SID aylinder pen pouring process or another process yet to be determined Ma problem won't be solved week : +e + eee - - : . : . 1 developing another at another moment . with any assurance we . o - ow & will be suscecsful in developing another: of reinforocemmt, preferably glass, wii aaah be adapted to the 50/50 In any same problem won't won't solved I in week ct the moment are 50/50 In any same in a stage month. ^an we Iny any lua 2 problem problem won't be solved a " nother aw ste . e or ey sere yg "a To ee . ' ee . which which can be used our prepent proses is nother rainfor ..-. : which can be used in prosess is at the best 50/50 what what das Erect me of our effort toward a new process and 17 50/50 what or t t at toward tt tt " " " market which do not sentain at laut tt asbestos To " best of our knedledge the only asbestos free product intre the market in recent years was OCF's Multitemp Do we attempt to intre Multitemp My answer would will 12 will esived Multitemp concept of post mating a prebonded graduet esived It lenon t ld end adeq touadaeqt uae te profit margins 01 022 1468 :) Mr. J. H. Dass 2 Outober 23, 1967 Instead if the decision is to develop a product based on glass fibers I would resoen we werk on an inorganic bonded glass fiber somposite which can be prodused in & stap operation pessibly via a modified modified version ef the filter press process, = - ; . We must not forget the beaded aggregate type product Careptaims pa bonded perlite informed with glass and asbestos fibers If Philip Carey would malve their breakage problem Carvytemp would become the best high temperature product on the market I believe an OC version of much a product containing 100 percent glass believe version version a much a atil ofi mit ccey as. As you know, this is the program whted 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 te suggfoer stt o congiderwha eretfoilloovn- ing program, Initiate a hard Hitting intencive search for a fiber substitute for asbestos The effort should be directed mainly toward glass fibers We should not however clase var eyes to other curude fibers which beecme commarsially available in the meantime, We sheuld also initiste ing glass reinforced bonded aggregate or inorganie inorganie ef develops ~ ing a glass reinforced bonded aggregate or an inorganie 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 diremstances I must recognise recognise the fact that direct all Under approach Soveret ve must recognise the fact that if ve direct all our efforts toward finding & substitute for asbestos and if not successful we could find ourselves requiring requiring asbestos asbestos the other hand hand if be built equipped with a process requiring asbestos On the other hand if the decision is not to continue looking fora substitute for asbestos but start to develop a bonded aggregate or high temperature glass fiber a la Multitemp prowd e au re c piTt IRE a death te sentence Berlin, fiber a eylinder process and the huge invest. ment in just to revamp Berlin A.oo, ve will face au outlay of 6 to 10 wiliion just to revamp Berlin te the new process. What are the ehances of techaical guecess? I would guesstimate 50/50 reinforced replacing asbestos in aggregate product pouring process, would percent fo 50/50 clr ase reinforced bonded aggregate product and about 80 percent for a step process Miltitemp aggregate product product about percent percent one What really bothers facilities ia facilities th earry cut any type ef progruz ve will need facial ndifatcii lie tis es At th moment I ax down to two technicians ami about 1/2 the facilities facilities th moment ax down down two technicians technicians are in storage termiatnGa rat nvielld e. Tweef are in stofr ora lag ck e of space ~ ed 01 022 1469 * y ony ae. 4 q - ba | ee One ee et et ae oo | pune , a . aw Mr. J. E. Thomas Thomas 3 formationS formationS poured poured after Kovember 15 supply of At the so^tv^ thi thptter to seo in on t^ utrond rees OOFTOOS a 2399 OOFTOOS and provide Kovember Kovember 15 me recruiting program prografmor new people batting 1s besouing recruiting program new people is batting se fer ackti tional 80 YO LPS Wariding with Fred Swank and Ike Nyer . be required to provide the space we need ; 3 if yeu have the time availale Thursday vhen oeme te eroari2is would like te have the oppertuntty of discussing this progrea with I RFS/ris -e y ar | - R 7. Seaman ; < ~ . a - 7 . eo .- = a oe r . n - o ~ 2 4 [ad fi - . . oo: woos . _* l -ee Pd - = ec a = = . Ld - - ~ rae me ar 2 *, oe she .- ~ 8 Sk r ry = oe ea oa ce Py vo ~ a - ~ pr se 2. : woth pete sae & . bad 2.7 . Ps ~ : : sas. : owe ~~ as * . 022 1470