Bakelite

Bakelite (/ˈbeɪkəlaɪt/ BAY-kəl-eyet; sometimes spelled Baekelite) or

Bakelite
polyoxybenzylmethylenglycolanhydridewas the first plastic made from synthetic
components. It is a thermosetting phenol formaldehyde resin, formed from a
condensation reaction of phenol with formaldehyde. It was developed by the
Belgian-American chemistLeo Baekeland in Yonkers, New York, in 1907.

Bakelite was patented on December 7, 1909. The creation of a synthetic plastic was
revolutionary for its electrical nonconductivity and heat-resistant properties in
electrical insulators, radio and telephone casings and such diverse products as
kitchenware, jewelry, pipe stems, children's toys, and firearms. The "retro" appeal of
old Bakelite products has made them collectible.[3]

Bakelite was designated a National Historic Chemical Landmark on November 9,

1993, by the American Chemical Society in recognition of its significance as the Identifiers
world's first synthetic plastic.[4] CAS Number 9003-35-4

ChemSpider none
Properties
Contents
Chemical (C6H6O·CH2O)n
History formula
Synthesis Molar mass Variable
Compression molding
Phenolic sheet
Appearance Brown solid

Properties Density 1.3 g/cm3[1]

Applications and uses Thermal 0.2 W/(m·K)[1]

Collectible status conductivity
Patents Refractive 1.63[2]
index (nD)
Similar plastics
See also Thermochemistry

References Heat capacity 0.92 kJ/(kg·K)[1]

(C)
External links
Except where otherwise noted, data
are given for materials in their
standard state (at 25 °C [77 °F],
History 100 kPa).

Baekeland was already wealthy due to his invention of Velox photographic paper
Infobox references
when he began to investigate the reactions of phenol and formaldehyde in his home
laboratory. Chemists had begun to recognize that many natural resins and fibers were polymers. Baekeland's initial intent was to find
a replacement for shellac, a material in limited supply because it was made naturally from the excretion of lac insects (specifically
[4]
Kerria lacca). Baekeland produced a soluble phenol-formaldehyde shellac called "Novolak", but it was not a market success.

Baekeland then began experimenting on strengthening wood by impregnating it with a synthetic resin, rather than coating it.[4] By
controlling the pressure and temperature applied to phenol and formaldehyde, Baekeland produced a hard moldable material that he
named "Bakelite",[5][6] after himself. It was the first synthetic thermosetting plastic produced, and Baekeland speculated on "the
thousand and one ... articles" it could be used to make.[7]:58–59 Baekeland considered the possibilities of using a wide variety of
[7]
filling materials, including cotton, powdered bronze, and slate dust, but was most successful with wood and asbestos fibers.

Baekeland filed a substantial number of patents in the area.[4] Bakelite, his "method of making insoluble products of phenol and
formaldehyde," was filed on July 13, 1907, and granted on December 7, 1909.[8] Baekeland also filed for patent protection in other
countries, including Belgium, Canada, Denmark, Hungary, Japan, Mexico, Russia, and Spain.[9] He announced his invention at a
meeting of the American Chemical Societyon February 5, 1909.[10]

Baekeland started semi-commercial production of his new material in his home

laboratory, marketing it as a material for electrical insulators. By 1910, he was
producing enough material to justify expansion. He formed the General Bakelite
Company as a U.S. company to manufacture and market his new industrial material.
[4]
He also made overseas connections to produce materials in other countries.

Bijker gives a detailed discussion of the development of Bakelite and the Bakelite
company's production of various applications of materials.[11] As of 1911, the
company's main focus was laminating varnish, whose sales volume vastly
outperformed both molding material and cast resin. By 1912, molding material was
gaining ground, but its sales volume for the company did not exceed that of
laminating varnish until the 1930s.

As the sales figures also show, the Bakelite Company produced "transparent" cast
resin (which did not include filler) for a small ongoing market during the 1910s and
1920s.[11]:172–174 Blocks or rods of cast resin, also known as "artificial amber", The first semi-commercial Bakelizer,
were machined and carved to create items such as pipe stems, cigarette holders and from Baekeland's laboratory
jewelry.[11][12] However, the demand for molded plastics led the Bakelite company
[11]:172–174
to concentrate on molding, rather than concentrating on cast solid resins.

The Bakelite Corporation was formed in 1922 after patent litigation favorable to Baekeland, from a merger of three companies:
Baekeland's General Bakelite Company; the Condensite Company, founded by J.W. Aylesworth; and the Redmanol Chemical
Products Company, founded by L.V. Redman.[13] Under director of advertising and public relations Allan Brown, who came to
Bakelite from Condensite, Bakelite was aggressively marketed as "the material of a thousand uses".[7]:58–59[14] A filing for a
trademark featuring the letter B above the mathematical symbol for infinitywas made August 25, 1925, and claimed the mark was in
[15]
use as of December 1, 1924. A wide variety of uses were listed in their trademark applications.

The first issue of Plastics magazine, October 1925, featured Bakelite on its cover,
and included the article "Bakelite – What It Is" by Allan Brown. The range of colors
available included "black, brown, red, yellow
, green, gray, blue, and blends of two or
more of these".[16] The article emphasized that Bakelite came in various forms.
"Bakelite is manufactured in several forms to suit varying requirements. In all these
forms the fundamental basis is the initial Bakelite resin. This variety includes clear
material, for jewelry, smokers' articles, etc.; cement, using in sealing electric light
bulbs in metal bases; varnishes, for impregnating electric coils, etc.; lacquers, for
protecting the surface of hardware; enamels, for giving resistive coating to industrial
equipment; Laminated Bakelite, used for silent gears and insulation; and molding
material, from which are formed innumerable articles of utility and beauty. The
molding material is prepared ordinarily by the impregnation of cellulose substances Color chart for Bakelite "jewel" quality
with the initial 'uncured' resin."[14]:17 In a 1925 report, the United States Tariff colors (cast resin or "Clear Material"),
Commission hailed the commercial manufacture of synthetic phenolic resin as 1924
"distinctly an American achievement", and noted that "the publication of figures,
however, would be a virtual disclosure of the production of an individual
company".[17]
In England, Bakelite Limited, a merger of three British phenol formaldehyde resin suppliers (Damard Lacquer Company Limited of
Birmingham, Mouldensite Limited of Darley Dale and Redmanol Chemical Products Company of London), was formed in 1926. A
new Bakelite factory opened inTyseley, Birmingham, around 1928.[18] It was demolished in 1998.

A new factory opened in Bound Brook, New Jersey, in 1931.[7]:75 In 1939, the companies were acquired by Union Carbide and
Carbon Corporation. Union Carbide's phenolic resin business including the Bakelite and Bakelit registered trademarks are assigned to
Hexion Inc.

In addition to the original Bakelite material, these companies eventually made a wide range of other products, many of which were
marketed under the brand name "Bakelite plastics". These included other types of cast phenolic resins similar to Catalin, and urea-
benzylmethyleneglycolanhydride.[3][7]
formaldehyde resins, which could be made in brighter colors than polyoxy

Once Baekeland's heat and pressure patents expired in 1927, Bakelite Corporation faced serious competition from other companies.
Because molded Bakelite incorporated fillers to give it strength, it tended to be made in concealing dark colors.[7] In 1927, beads,
bangles and earrings were produced by the Catalin company, through a different process which enabled them to introduce 15 new
colors. Translucent jewelry, poker chips and other items made of phenolic resins were introduced in the 1930s or 1940s by the Catalin
company under the Prystal name.[19][20] The creation of marbled phenolic resins may also be attributable to the Catalin company
.

Synthesis
Making Bakelite was a multi-stage process. It began with the heating of phenol and External video
formaldehyde in the presence of a catalyst such as hydrochloric acid, zinc chloride,
“Making Bakelite Plastic”,
or the base ammonia. This created a liquid condensation product, referred to as
NileRed
Bakelite A, which was soluble in alcohol, acetone, or additional phenol. Heated
further, the product became partially soluble and could still be softened by heat.
Sustained heating resulted in an "insoluble hard gum". However, the high temperatures required to create this tended to cause violent
foaming of the mixture, which resulted in the cooled material being porous and breakable. Baekeland's innovative step was to put his
"last condensation product" into an egg-shaped "Bakelizer". By heating it under pressure, at about 150 °C (300 °F), Baekeland was
able to suppress the foaming that would otherwise occur. The resulting substance was extremely hard and both infusible and
insoluble.[3]:67 [7]:38–39
 Weigh room Still room Cooling room Resin and varnish
inspection laboratory

Testing resin samples Development laboratory

Compression molding
Molded Bakelite forms in a condensation reaction of phenol and formaldehyde, with
wood flour or asbestos fiber as a filler, under high pressure and heat in a time frame
of a few minutes of curing. The result is a hard plastic material.[21]

Bakelite's molding process had a number of advantages. Bakelite resin could be

provided either as powder, or as preformed partially cured slugs, increasing the
speed of the casting. Thermosetting resins such as Bakelite required heat and
pressure during the molding cycle, but could be removed from the molding process
without being cooled, again making the molding process faster. Also, because of the
smooth polished surface that resulted, Bakelite objects required less finishing.[22]
.[7]:42–43
Millions of parts could be duplicated quickly and relatively cheaply

Phenolic sheet
Another market for Bakelite resin was the creation of phenolic sheet materials.
Phenolic sheet is a hard, dense material made by applying heat and pressure to layers Bakelite distributor rotor
of paper or glass cloth impregnated with synthetic resin.[7]:53 Paper, cotton fabrics,
synthetic fabrics, glass fabrics and unwoven fabrics are all possible materials used in
lamination. When heat and pressure are applied, polymerization transforms the layers into thermosetting industrial laminated
plastic.[23]

Bakelite phenolic sheet is produced in many commercial grades and with various additives to meet diverse mechanical, electrical and
[24]
thermal requirements. Some common types include:

Paper reinforced NEMA XX per MIL-I-24768 PBG. Normal electrical applications, moderate mechanical strength,
continuous operating temperature of 250 °F (120 °C).
Canvas reinforced NEMA C per MIL-I-24768 TYPE FBM NEMA CE per MIL-I-24768 TYPE FBG. Good mechanical
and impact strength with continuous operating temperature of 250 °F (120 °C).
 Linen reinforced NEMA L per MIL-I-24768 TYPE FBI NEMA LE per MIL-I-24768 TYPE FEI. Good mechanical and
electrical strength. Recommended for intricate high strength parts. Continuous operating temperature 250 °F
(120 °C).
Nylon reinforced NEMA N-1 per MIL-I-24768 TYPE NPG. Superior electrical properties under humid conditions,
fungus resistant, continuous operating temperature of 160 °F (70 °C).

Properties
Bakelite has a number of important properties. It can be molded very quickly,
decreasing production time. Moldings are smooth, retain their shape and are resistant
to heat, scratches, and destructive solvents. It is also resistant to electricity, and
prized for its low conductivity. It is not flexible.[7]:44–45[22][25]

Phenolic resin products may swell slightly under conditions of extreme humidity or
perpetual dampness.[26] When rubbed or burnt, Bakelite has a distinctive, acrid,
sickly-sweet or fishy odor.[27]

Applications and uses Ericsson Bakelite telephone, c. 1931

These characteristics made Bakelite particularly suitable as a molding compound, an

adhesive or binding agent, a varnish, and as a protective coating. Bakelite was
particularly suitable for the emerging electrical and automobile industries because of
, heat and chemical action.[7]:44–45
its extraordinarily high resistance to electricity

The earliest commercial use of Bakelite in the electrical industry was the molding of
tiny insulating bushings, made in 1908 for the Weston Electrical Instrument
Corporation by Richard W. Seabury of the Boonton Rubber Company.[7]:43[28]
Bakelite was soon used for non-conducting parts of telephones, radios and other
electrical devices, including bases and sockets for light bulbs and electron tubes,
supports for any type of electrical components, automobile distributor caps and other
insulators.[7][29] By 1912, it was being used to make billiard balls, since its elasticity
and the sound it made were similar to ivory.[30][31]
Bakelite letter opener c. 1920

During World War I, Bakelite was used widely, particularly in electrical systems.
Important projects included the Liberty Motor,[32] the wireless telephone and radio
phone[33] and the use of micarta-bakelite propellors in the NBS-1 bomber and the
DH-4B aeroplane.[34][35]

Bakelite's availability and ease and speed of molding helped to lower the costs and
increase product availability so that both telephones and radios became common
household consumer goods.[7]:116–117 [36][37] It was also very important to the
developing automobile industry.[38] It was soon found in myriad other consumer
products ranging from pipe stems and buttons to saxophone mouthpieces, cameras,
early machine guns, and appliance casings.[39]

Beginning in the 1920s, it became a popular material for jewelry.[40] Designer Coco
Chanel included Bakelite bracelets in her costume jewelry collections.[41] :27–29

Designers such as Elsa Schiaparelli used it for jewelry and also for specially
designed dress buttons.[42][43] Later, Diana Vreeland, editor of Vogue, was
enthusiastic about Bakelite.[44] Bakelite was also used to make presentation boxes
Bakelite radio at Bakelite museum
for Breitling watches. Jewelry designers such as Jorge Caicedo Montes De Oca still
.[45]
use vintage Bakelite materials to make designer jewelry
By 1930, designer Paul T. Frankl considered Bakelite a "Materia Nova", "expressive of our own age".[7]:107 By the 1930s, Bakelite
was used for game pieces like chessmen, poker chips,[46] dominoes[47] and mahjong sets.[48][49] Kitchenware made with Bakelite,
including canisters and tableware, was promoted for its resistance to heat and to chipping.[50][51] In the mid-1930s, Northland
marketed a line of skis with a black "Ebonite" base, a coating of Bakelite.[52][53] By 1935, it was used in solid-body electric guitars.
ficult to keep in tune.[54]
Performers such as Jerry Byrd loved the tone of Bakelite guitars but found them dif

The British children's construction toy Bayko, launched in 1933, originally used Bakelite for many of its parts, and took its name
from the material.

During World War II, Bakelite was used in a variety of wartime equipment including
pilot's goggles and field telephones.[55] It was also used for patriotic wartime
jewelry.[56][57] In 1943, the thermosetting phenolic resin was even considered for
the manufacture of coins, due to a shortage of traditional material. Bakelite and other
non-metal materials were tested for usage for the one cent coin in the US before the
Mint settled on zinc-coated steel.[58][59]

In 1947, Dutch art forger Han van Meegeren was convicted of forgery, after chemist
and curator Paul B. Coremans proved that a purported Vermeer contained Bakelite,
.[60]
which van Meegeren had used as a paint hardener

Bakelite was sometimes used as a substitute for metal in the magazine, pistol grip,
fore grip, hand guard, and butt stock of firearms. The AKM and some early AK-74
rifles are frequently mistakenly identified as using Bakelite, but most were made
with AG-S4.[61]

By the late 1940s, newer materials were superseding Bakelite in many areas.[38] Old tumbler switch composed of
Bakelite
Phenolics are less frequently used in general consumer products today due to their
cost and complexity of production and their brittle nature. They still appear in some
applications where their specific properties are required, such as small precision-shaped components, molded disc brake cylinders,
saucepan handles, electrical plugs, switches and parts for electrical irons,[62] as well as in the area of inexpensive board and tabletop
games produced in China, Hong Kong and India.[62] Items such as billiard balls, dominoes and pieces for board games such as chess,
checkers, and backgammon are constructed of Bakelite for its look, durability, fine polish, weight, and sound. Common dice are
sometimes made of Bakelite for weight and sound, but the majority are made of a thermoplastic polymer such as acrylonitrile
butadiene styrene (ABS). Bakelite continues to be used for wire insulation, brake pads and related automotive components, and
industrial electrical-related applications. Bakelite stock is still manufactured and produced in sheet, rod and tube form for industrial
[38]
applications in the electronics, power generation and aerospace industries, and under a variety of commercial brand names.

Phenolic resins have been commonly used in ablative heat shields.[63] Soviet heatshields for ICBM warheads and spacecraft reentry
consisted of asbestos textolite, impregnated with Bakelite.[64] Bakelite is also used in the mounting of metal samples in
metallography.[65]

Collectible status
Bakelite items, particularly jewelry and radios, have become a popular collectible.[38] The term Bakelite is sometimes used in the
resale market to indicate various types of early plastics, including Catalin and Faturan, which may be brightly colored, as well as
items made of Bakelite material.[37][66]

Patents
The United States Patent and Trademark Office granted Baekeland a patent for a "Method of making insoluble products of phenol
and formaldehyde" on December 7, 1909.[8] Producing hard, compact, insoluble and infusible condensation products of phenols and
.[67]
formaldehyde marked the beginning of the modern plastics industry
Similar plastics
Catalin was also a phenolic resin, similar to Bakelite, but contained dif
ferent mineral fillers that allowed the
production of light colors.[68]
[69]
Condensites are similar thermoset materials having much the same properties, characteristics, and uses.
Crystalate was an early plastic.[70]
.[71]
Faturan is phenolic resin, also similar to Bakelite, that turns red over time, regardless of its original color
[72]
Galalith is an early plastic derived from milk products.
Micarta is an early composite insulating plate that used Bakelite as a binding agent. It was developed in 1910 by
Westinghouse Elec. & Mfg Co.[73]
[74]
Novotext is a brand name for cotton textile-phenolic resin.

See also
Bakelite Museum, Williton, Somerset, England
Ericsson DBH 1001 telephone

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External links
Baekeland, L. H. (March 1909)."The Synthesis, Constitution, and Uses of Bakelite" . Journal of Industrial &
Engineering Chemistry. 1 (3): 149–161. doi:10.1021/ie50003a004. ISSN 0095-9014.
All Things Bakelite: The Age of Plastictrailer for a film by John Maher, with additional video & resources
Amsterdam Bakelite Collection
Large Bakelite Collection
Bakelite: The Material of a Thousand Uses
Virtual Bakelite Museum of Ghent 1907–2007

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