Document Z8B97GRY2o3yXX14XNbpNv4dJ

FILE NAME Corning OC DATE 1962 Oct 1 DOC OC019 DOCUMENT DESCRIPTION Internal Report - Kaylo Improvement Program - 62-11 Kaylo Improvement Program by R. F. Shannon 01 041 0711 . PT are~n.es * - CORNING FIBERGLAS Kayla Improvement Improvement Improvement Improvement , a PLAINTIFF'S EXHIBIT 1-76-1403 11-76-1403 OWENI CORMING FIBE FIBERR GLAS G FIBL ERGLAA S FIBS ERGLAS FIBERGLAS TECHNICAL REPORT TITLE ; REPORT NUMBER Kaylo Improvement Program 62-11 PROJECT NUMBER AUTHOR 5 ) R. F. Shannon SIGNED LOCATION Chemistry Research Granville Ohio COUNTERSIGNED Laboratory 84032 CATE October 31 CLASSIFICATION II 1962 RY AND CONCLUSIONS Experimental data collected during the past year indicates , and market a calcium silicate product having strengths OCF can produce Thermobestos To accomplish this phenolic equal or superior to chloride coated glass fibers coated glass fibers vinyl or specially processed amosite asbestos fibers will have to be used as present process reinforcement along with a modified version of the | { om | ; Regardless of the type of reinforcing fiber used have to be modified if strength improvements the present process will to be duplicated in the obtained in the laboratory are factory type of reinforcing fiber The amount of change will depend on the used Vinyl chloride coated glass fibers will require the least change the specially processed amosite the most change asbestos fibers Phenolic coated glass fibers and specially processed amosite asbestos e fibers should have no effect on stress corrosion whereas vinyl chloride coated glass fibers cause severe stress corrosion twe steel Marketing has decided that cracking of stainless will intensify the problem of no fiber or any other ingredient which Ae stress corrosion can be added to Kaylo Phenolic PhenolicPhenolic PhenolicPhenolic coated coatedcoatedcoatedcoated glassglassglass glass fibersfibers fibers meetmeet the stress stress stressstress stress stress corrosion corrosioncorrosioncorosion corosion the same time provide adequate reinforcement corrosion requirementrequirement requirementrequirement requirement andand at Costs of formulations con- % otfain1in0 g L bbaytwcehight phenolic coated glass fibers will not exceed the cost standard production second and third quarters 1962 , A number achieved standard of significant results in addition to those listed above have during the past year These been include 1 chloride content of production Kaylo has been reduced to the lowest point in history DISTRIBUTION . Mr. R. C. Amos - Berlin Dr. L. P. Biefeld - Toledo Mr. B. E. Boyd - Toledo Mr. J. H. Boynton - New York Dr. W. E. Cass - Granville Mr. W. J. Holcomb - Toledo Mr. D. W. Ladd - New York Mr. R. J. Paoletti - Toledo Mr. J. A. Pershing - Toledo OF * CLASSIFICATION REPORT 1 MAY BE SENT OUTSIODCEF tt GOVERNMENT SECUPUITY CLASSIFICATION CLASSIFICATION continued on page 2 i Mr. O. W. Pfeifer - Toledo Mr. W. K. Sidwell - Toledo ; : Dr. A. C. Siefert - Granville | Mr. H. V. Smith - Toledo Mr. W. - | Mr. J. F. Vyverberg - New York Mr. C. Wilson W. A. Lotz - Granville | Mr. W. S. Young - New York Central Files DUPLIC USS 171430 01 041 0712 -~) dewater The well opened long fiber asbestos does cause it increases the consistency of the batch processing problems First thereby increasing the incidence of slip planes and pouring folds Kaylo batches reinforced with such seem to trap and retain a greater percentage of air bubbles fibers show up in the finished product and are The latter product appearance a source of customer complaint High amosite content batches also seem to more quickly Table III compares obtained on the No. 3 pilot plant laboratory tilt drop ratings line and those obtained with those No. 2 production pouring line on the regular All were poured with cores out The batches poured on Line 3 pilot plant were mixed in the small and bucket poured Hydropulper Table III Fiberizing Equipment Proctor & Schwartz Feeder & Picker Proctor & Schwartz Carding Machine Proctor & Schwartz Shredder 4 x 1 MFC Tilt Drop Ratings Laboratory | Pilot Plant Ratings Factory 11.8 9.5 8.5 10.6 8.6 7.6 5.8 3.8 4.4 4.6 - Devil Tooth Bauer Mill Waldron 5.7 - 3.0-3.5 2 5.1 5.4-6.3 | 3.7-4.8 1 Factory result in parenthesis were obtained cores in on samples poured with Today asbestos fibers are being used successfully in a number of competitive with Kaylo Laboratory data indicates products improvements can be obtained if well opened that major strength long fiber amosite asbestos fibers are used as reinforcement The problem of these improvements lies with the preventing the realization able to assume that a process At the moment it is reason- product equal or superior to Thermobestos can be achieved with asbestos fibers provided major modifications of the process to prevent fiber damage are carried out present All types of fibers including asbestos have certain advantages as well as disadvantages when used as reinforcement for Kaylo Among the more important advantages of asbestos fibers are 1 low cost 2 alkali and temperature resistance 3 retention of strength at elevated 1200 -10- 01 041 0721 -) service temperatures and 4 a wealth of for processing and using such fibers in technology available calcium as to methods major disadvantages of using asbestos silicate type products The ment value per pound of fiber as fibers in Kaylo are 1 less reinforce- damaged during processing compared to glass 3 increases 2 brittle easily mroor pe e during pouring 4 potential healthbahtazcahrdconsistencies and tendency to asbestosis susceptible to market fluctuations and 5 prices from outside USA and 6 questionable world conditions all imported availability asbestos shipped from South Africa especially amosite Vinyl Coated Glass Fiber Reinforcement Evaluation of vinyl chloride coated real clue that glass fibers could be gluassesd aisnsect screening gave the first prove the feasibility of this reinforcement for Kaylo To that further evaluations of concept it was deemed essential at the time done with full vinyl coated fibers be carried out knowledge that vinyl coatings could This was corrosion cracking of stainless steel might never be used where stress engineering data collected from these occur It was hoped that . plant scale up regardless of the experiments could be used for eventual Of course these coating ultimately chosen for the experiments were conducted with the glass chloride coating would be found assumption that & the possibility that Merketing would deevceindteually Also there was always especially designed for to market two products one the other for stainless steel stress , applications corrosion improved handleability Under these circumstances chloride coated fiber data would be the vinyl available for immediate scale up at the There are a number of disadvantages of reinforcing Kaylo with vinyl chloride coated glass fibers These include cost 3 tendency to 1 high chloride content 2 high of Berlin processing eqcuaiupsmeenrtoping during pouring 4 potential corrosion stainless cylinders and 5 elimination of innerliners in three of the SID stainless steel Kaylo as a marketable insulation for using vinyl applications chloride There fibers are also a number of advantages of coated fibers which under certain outweigh the disadvantages These include during conditions far 1 more resistant processing 2 flexible 3 more adaptable to to damage as it now exists and 4 excellent adhesion the Berlin process mechanical Vinyl chloride coated fibers like phenolic to Kaylo temperatures and minimum moisture coated fibers are sensitive to maximum Vinyl chloride coatings are contents in the ware during autoclaving tures in excess of thermally decomposed when subjected to tempera- 450-500 Kaylo drops below 30-40 by weesipgehctially when the moisture content of the The major concern and as reinforcement cause for rejection of vinyl chloride coated fibers for Kaylo is the danger of stress steel both at the plant and in the corrosion of stainless field This danger does exist 01 041 0722