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71-487: Bakelite ( / ˈ b eɪ k ə l aɪ t / BAY -kə-lyte ), formally poly­oxy­benzyl­methylene­glycol­anhydride , is a thermosetting phenol formaldehyde resin , formed from a condensation reaction of phenol with formaldehyde . The first plastic made from synthetic components, it was developed by Leo Baekeland in Yonkers, New York , in 1907, and patented on December 7, 1909. Bakelite

142-402: A "Materia Nova", "expressive of our own age". By the 1930s, Bakelite was used for game pieces like chess pieces , poker chips , dominoes , and mahjong sets. Kitchenware made with Bakelite, including canisters and tableware, was promoted for its resistance to heat and to chipping. In the mid-1930s, Northland marketed a line of skis with a black "Ebonite" base, a coating of Bakelite. By 1935, it

213-605: A few diverse forms: glass beads, short glass fibers , and long glass fibers. in plastics by tonnage. Glass fibers are used to increase the mechanical properties of the thermoplastic or thermoset such as flexural modulus and tensile strength, There is normally not an economic benefit for adding glass as a filler material. Some disadvantages of having glass in the matrix include low surface quality, high viscosity when melted, poor weldability, and warpage. The addition of glass beads will help with oil absorption and chemical resistance. Coal and shale oil fly ashes have been used as

284-542: A filler for thermoplastics that could be used for injection molding applications. Nanofiller have a particle size of less than 100 nanometres . They have a high aspect ratio and are mainly used as scratch resistant and fire-resistant fillers. Nanofillers can be broken out into three groups nanoplates, nanofibers, and nanoparticles . Nanoparticles are more widely used than nanoplates and nanofibers but nanoplates are starting to become more widely used. Nanoplates are like conventional platy fillers like talc and mica except

355-407: A filler is selected to decrease the friction coefficient of the material. Particle size and shape are contributing factors. Smaller particle size increase wear resistance because they cause less debris. silica , alumina , molybdenum disulfide , and graphite powder are common fillers that improve wear resistance. Filler can have a negative or positive effect on fatigue resistance depending on

426-407: A homogenous blend within a formulated system due to their extremely low bulk density. However, these limitations can be mostly if not entirely overcome through the use of formulation modifications, additives, and other surface treatments. Despite these potential challenges, Polymer Foam Beads can be added to formulated systems when weight or cost savings in a finished good are required. Masonry filler

497-497: A meeting of the American Chemical Society on February 5, 1909. Baekeland started semi-commercial production of his new material in his home laboratory, marketing it as a material for electrical insulators. In the summer of 1909, he licensed the continental European rights to Rütger AG. The subsidiary formed at that time, Bakelite AG, was the first to produce Bakelite on an industrial scale. By 1910, Baekeland

568-442: A more bright and more glossy surface. Kaolin is mainly used in plastics for its anti-blocking characteristics as well as an infrared absorber in laser marking. It increases impact strength and heat resistance. Metakolinite is used to stabilize PVC. Kaolin has also been shown to increase the abrasion resistance and can replace carbon black as a filler material and improve the flow properties of glass-reinforced substances. Talc ,

639-588: A protective coating, as well as for the emerging electrical and automobile industries because of its extraordinarily high resistance to electricity, heat, and chemical action. 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. Bakelite

710-412: A similar material fakelite (fake bakelite) exists made from modern safer materials which do not contain asbestos . 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. Producing hard, compact, insoluble, and infusible condensation products of phenols and formaldehyde marked the beginning of

781-670: A soft mineral and generally more expensive than calcium carbonate . It is derived from layering sheets of magnesium hydroxide with silica. In the plastic industry, it is used for packaging and food applications due to its long-term thermal stability. Wollastonite has an acicular structure with a relatively high specific gravity and high hardness. This filler can improve moisture content, wear resistance, thermal stability, and high dielectric strength. Wollastonite competes with platy filler substances like mica and talc and also can be used to replace glass fibers when creating thermoplastics and thermosets. Glass filler materials come in

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852-404: A synthetic plastic was revolutionary for the chemical industry, which at the time made most of its income from cloth dyes and explosives. Bakelite's commercial success inspired the industry to develop other synthetic plastics. As the world's first commercial synthetic plastic , Bakelite was named a National Historic Chemical Landmark by the American Chemical Society . Bakelite was produced for

923-488: A synthetic resin rather than coating it. By controlling the pressure and temperature applied to phenol and formaldehyde , he produced a hard moldable material that he named Bakelite, 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. He considered the possibilities of using a wide variety of filling materials, including cotton, powdered bronze, and slate dust, but

994-485: A variety of ways to create distinctive cured properties that cannot be achieved with thermoplastic polymers or inorganic materials. Thermosetting plastics are generally stronger than thermoplastic materials due to the three-dimensional network of bonds (crosslinking), and are also better suited to high- temperature applications up to the decomposition temperature since they keep their shape as strong covalent bonds between polymer chains cannot be broken easily. The higher

1065-408: A way to improve and control the processing charasteristics. Another reason to use fillers is to reduce costs by replacing part of the expensive core material with a cheaper filler. Most of the filler materials used in plastics are mineral or glass based filler materials. Particulates and fibers are the main subgroups of filler materials. Particulates are small particles of filler that are mixed in

1136-412: Is also resistant to electricity, and prized for its low conductivity. It is not flexible. Phenolic resin products may swell slightly under conditions of extreme humidity or perpetual dampness. When rubbed or burnt, Bakelite has a distinctive, acrid, sickly-sweet or fishy odor. The characteristics of Bakelite made it particularly suitable as a molding compound, an adhesive or binding agent, a varnish, and

1207-405: Is also used in the mounting of metal samples in metallography . Bakelite items, particularly jewelry and radios, have become popular collectibles. The term Bakelite is sometimes used in the resale market as a catch-all for various types of early plastics, including Catalin and Faturan , which may be brightly colored, as well as items made of true Bakelite material. Due to its aesthetics,

1278-436: Is heavily impacted by filler materials. The equation below shows the creep strain of a filled material: where: The better the filler bonds with the matrix the better creep resistance will be. Many interactions will have a positive influence. Glass beads and fibers both have been shown to improve creep resistance in some materials. Aluminum oxide also has a positive effect on creep resistance. Water absorption will decrease

1349-434: Is particle size, particle shape and particle rigidity. Fibers improve impact resistance the most due to their large aspect ratio . Low hardness fillers will decrease impact strength. Particle size, within a specific range can increase the impact strengths based on the filler material. The wear volume (W s ) for plastic materials can be calculated: where: Matrix and filler both contribute to wear resistance. In general

1420-399: Is still manufactured and produced in sheet, rod, and tube form for industrial 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. Soviet heatshields for ICBM warheads and spacecraft reentry consisted of asbestos textolite, impregnated with Bakelite. Bakelite

1491-415: Is to compare weld strength to resin strength. This can be hard to do since many filler materials contain different level of additives that change the mechanical behavior. Filler is widely used in the production process of plastic products. Filler is used to changing the properties of the original plastic. By using plastic filler, manufacturers can save production costs as well as raw materials. Undeniably

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1562-429: Is used to repair cracks and holes in exterior walls and is typically made using cement and hydrated lime . Manufacturers include Toupret. A variety of natural polymers can be applied as filler. Some known examples include cellulose fibres, wood flour and fibres, flax , cotton , sisal and starch . Concrete filler materials include gravel , stone, sand , and rebar . Gravel, stone, and sand are used to reduce

1633-567: 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. The creation of marbled phenolic resins may also be attributable to the Catalin company. Making Bakelite is a multi-stage process. It begins with

1704-584: The Army and black buttons for the RAF . 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, which van Meegeren had used as a paint hardener. Bakelite was sometimes used in the pistol grip, hand guard, and buttstock of firearms. The AKM and some early AK-74 rifles are frequently mistakenly identified as using Bakelite, but most were made with AG-4S . By

1775-426: The amine-isocyanate nucleophilic addition reaction does not require catalysts. Polyureas also form when isocyanate resins come into contact with moisture; Phenolic , amino , and furan resins all cured by polycondensation involving the release of water and heat, with cure initiation and polymerisation exotherm control influenced by curing temperature, catalyst selection or loading and processing method or pressure –

1846-660: The area of inexpensive board and tabletop games produced in China, Hong Kong, and India. 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

1917-598: The article "Bakelite – What It Is" by Allan Brown. The range of colors that were available included "black, brown, red, yellow, green, gray, blue, and blends of two or more of these". 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, for sealing electric light bulbs in metal bases; varnishes, for impregnating electric coils, etc.; lacquers, for protecting

1988-456: The commercial manufacture of synthetic phenolic resin as "distinctly an American achievement", and noted that "the publication of figures, however, would be a virtual disclosure of the production of an individual company". 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 ),

2059-521: The cooling rate. They can also increase the operating temperatures of materials and provide insulation for electrical wiring. CaCO 3 is used in filler masterbatch as a base with a large percentage in composition. Calcium carbonate powder accounts for 97% of the composition will bring white/opaque products more whiteness. So manufacturers can reduce the usage of white masterbatch. With a smaller percentage, calcium carbonate powder can be used for color products. In addition, it brings final plastic products

2130-486: The cost of concrete. Rebars are used to strengthen the concrete. (g/cm ) (Microns) Tensile strength is the most used method to evaluate filler materials. The tensile strength of the composite can be calculated using the equation where The elastic modulus ( Young's modulus ) of a filled polymer can be found using the equation below: where: Polymers with smaller additions of filler follow this equation closely. In general addition of filler materials will increase

2201-419: The creep resistance of a filled material. Additions of filler materials can drastically affect the weldability of the plastic. This also depends on the type of welding process used. For ultrasonic welding , fillers like calcium carbonate and kaolin can increase the resin's ability to transmit ultrasonic waves. For electromagnetic welding and hot plate welding additions of talc and glass will reduce

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2272-633: The crosslink density and aromatic content of a thermoset polymer, the higher the resistance to heat degradation and chemical attack. Mechanical strength and hardness also improve with crosslink density, although at the expense of brittleness. They normally decompose before melting. Hard, plastic thermosets may undergo permanent or plastic deformation under load. Elastomers, which are soft and springy or rubbery and can be deformed and revert to their original shape on loading release. Conventional thermoset plastics or elastomers cannot be melted and re-shaped after they are cured. This usually prevents recycling for

2343-491: The degree of crosslinking and resulting physical type (elastomer or plastic) is adjusted from the molecular weight and functionality of isocyanate resins, prepolymers, and the exact combinations of diols, triols and polyols selected, with the rate of reaction being strongly influenced by catalysts and inhibitors; polyureas form virtually instantaneously when isocyanate resins are combined with long-chain amine functional polyether or polyester resins and short-chain diamine extenders –

2414-429: The degree of pre-polymerisation and level of residual hydroxymethyl content in the resins determine the crosslink density. Polybenzoxazines are cured by an exothermal ring-opening polymerisation without releasing any chemical, which translates in near zero shrinkage upon polymerisation. Thermosetting polymer mixtures based on thermosetting resin monomers and pre-polymers can be formulated and applied and processed in

2485-671: The demand for molded plastics led the company to concentrate on molding rather than 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 Lawrence V. Redman . Under director of advertising and public relations Allan Brown, who came to Bakelite from Condensite, Bakelite

2556-708: The ends or on the backbone are generally linked by copolymerisation with unsaturated monomer diluents, with cure initiated by free radicals generated from ionizing radiation or by the photolytic or thermal decomposition of a radical initiator – the intensity of crosslinking is influenced by the degree of backbone unsaturation in the prepolymer; Epoxy functional resins can be homo-polymerized with anionic or cationic catalysts and heat, or copolymerised through nucleophilic addition reactions with multifunctional crosslinking agents which are also known as curing agents or hardeners. As reaction proceeds, larger and larger molecules are formed and highly branched crosslinked structures develop,

2627-1057: The fabrication of factory-finished structural composite OEM or replacement parts, and as site-applied, cured and finished composite repair and protection materials. When used as the binder for aggregates and other solid fillers, they form particulate-reinforced polymer composites, which are used for factory-applied protective coating or component manufacture, and for site-applied and cured construction, or maintenance purposes. Application/process uses and methods for thermosets include protective coating , seamless flooring , civil engineering construction grouts for jointing and injection, mortars , foundry sands, adhesives , sealants , castings , potting , electrical insulation , encapsulation , solid foams , wet lay-up laminating, pultrusion , gelcoats , filament winding , pre-pregs , and molding. Specific methods of molding thermosets are: Filler (materials) Filler materials are particles added to resin or binders ( plastics , composites , concrete ) that can improve specific properties, make

2698-485: The filler type and shape. In general fillers create small discontinuities in the matrix. This can contribute to crack initiation point. If the filler is brittle fatigue resistance will be low, whereas if the filler is very ductile the composite will be fatigue resistant. Adhesion is also an important factor influencing fatigue resistance. If stress is higher than the particles adhesion a crack will form/propagate. Fiber ends are areas where cracks initiate most often due to

2769-506: The first half of the 20th century. Beginning in the 1920s, it became a popular material for jewelry. Designer Coco Chanel included Bakelite bracelets in her costume jewelry collections. Designers such as Elsa Schiaparelli used it for jewelry and also for specially designed dress buttons. Later, Diana Vreeland , editor of Vogue , was enthusiastic about Bakelite. Bakelite was also used to make presentation boxes for Breitling watches. By 1930, designer Paul T. Frankl considered Bakelite

2840-415: The first time in 1872 by Adolf von Baeyer , though its use as a commercial product was not considered at the time. Leo Baekeland was already wealthy due to his invention of Velox photographic paper 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

2911-428: The foaming that would otherwise occur. The resulting substance is extremely hard and both infusible and insoluble. 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. Asbestos was gradually abandoned as filler because many countries banned

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2982-495: The form of pellets, and shaped into the final product form by melting, pressing, or injection molding . Curing a thermosetting resin transforms it into a plastic , or elastomer ( rubber ) by crosslinking or chain extension through the formation of covalent bonds between individual chains of the polymer . Crosslink density varies depending on the monomer or prepolymer mix, and the mechanism of crosslinking: Acrylic resins, polyesters and vinyl esters with unsaturated sites at

3053-418: The heating of phenol and formaldehyde in the presence of a catalyst such as hydrochloric acid, zinc chloride , or the base ammonia. This creates a liquid condensation product, referred to as Bakelite A , which is soluble in alcohol, acetone, or additional phenol. Heated further, the product becomes partially soluble and can still be softened by heat. Sustained heating results in an "insoluble hard gum". However,

3124-522: The high stress on fiber ends with lower adhesion. Talc is a filler that can be used to increase fatigue resistance. Filler materials have a large influence on thermal deformation in crystalline polymers. Amorphous polymers are negligibly affected by filler material. Glass fiber additions are used the most to deflect the most heat. Carbon fibers have been shown to do better than glass in some base materials. In general fibrous materials are better at deflecting heat than particle fillers. Creep resistance

3195-399: The high temperatures required to create this tend to cause violent foaming of the mixture when done at standard atmospheric pressure, which results 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 (302 °F), Baekeland was able to suppress

3266-491: The late 1940s, newer materials were superseding Bakelite in many areas. 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, printed circuit boards , as well as in

3337-461: The layers into thermosetting industrial laminated plastic. Bakelite phenolic sheet is produced in many commercial grades and with various additives to meet diverse mechanical, electrical, and thermal requirements. Some common types include: 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

3408-449: The matrix where size and aspect ratio are important. Fibers are small circular strands that can be very long and have very high aspect ratios. Referred to as "chalk" in the plastic industry, calcium carbonate is derived from limestone and marble. It is used in many applications including PVC's and unsaturated polyesters. As much as 90% CaCO 3 can be used to make a composite. These additions can improve molding productivity by decreasing

3479-404: The modern plastics industry . Thermosetting polymer The starting material for making thermosets is usually malleable or liquid prior to curing, and is often designed to be molded into the final shape. It may also be used as an adhesive . Once hardened, a thermoset cannot be melted for reshaping, in contrast to thermoplastic polymers which are commonly produced and distributed in

3550-404: The modulus. The additions of calcium carbonate and talc will increase the elastic modulus , while the addition of elastic filler materials can reduce the value slightly. Filler materials increase the modulus due to their rigidity or stiffness and good adhesion with the polymeric matrix. In general fillers will increase impact resistance. The contributing factors that improve impact resistance

3621-416: The product cheaper, or a mixture of both. The two largest segments for filler material use is elastomers and plastics . Worldwide, more than 53 million tons of fillers (with a total sum of approximately US$ 18 billion) are used every year in application areas such as paper , plastics , rubber , paints , coatings, adhesives , and sealants . As such, fillers, produced by more than 700 companies, rank among

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3692-426: The production of asbestos. 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

3763-460: The rate of cure being influenced by the physical form and functionality of epoxy resins and curing agents – elevated temperature postcuring induces secondary crosslinking of backbone hydroxyl functionality which condense to form ether bonds; Polyurethanes form when isocyanate resins and prepolymers are combined with low- or high-molecular weight polyols, with strict stoichiometric ratios being essential to control nucleophilic addition polymerisation –

3834-547: The same purpose, except as filler material. New developments involving thermoset epoxy resins which on controlled and contained heating form crosslinked networks permit repeatedly reshaping, like silica glass by reversible covalent bond exchange reactions on reheating above the glass transition temperature. There are also thermoset polyurethanes shown to have transient properties and which can thus be reprocessed or recycled. When compounded with fibers, thermosetting resins form fiber-reinforced polymer composites, which are used in

3905-570: The smooth polished surface that resulted, Bakelite objects required less finishing. Millions of parts could be duplicated quickly and relatively cheaply. Another market for Bakelite resin was the creation of phenolic sheet materials. A phenolic sheet is a hard, dense material made by applying heat and pressure to layers of paper or glass cloth impregnated with synthetic resin. 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

3976-505: 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 with the initial "uncured" resin. In a 1925 report, the United States Tariff Commission hailed

4047-413: The thickness is much smaller. The advantages of adding nanofillers include creating a gas barrier and their flame-retardant properties. Polymer Foam Beads can have a bulk density as low as 0.011 g/cc and range in size from 45 microns to over 8 mm. Common drawbacks to using Polymer Foam Beads in formulated systems include static, temperature, and chemical resistance limitations and difficulty achieving

4118-430: The weld strength by as much as 32%. The strength of the plastic after welding would decrease with an increasing amount of fillers in the matrix compared to the bulk material. Use of abrasive fillers can affect the tool used for welding. Abrasive fillers will degrade the welding tools faster, for example, the surface of the ultrasonic horn in contact with the plastic. The best way to test the weldability of filler material

4189-409: The world's major raw materials and are contained in a variety of goods for daily consumer needs. The top filler materials used are ground calcium carbonate (GCC), precipitated calcium carbonate (PCC), kaolin, talc, and carbon black. Filler materials can affect the tensile strength, toughness, heat resistance, color, clarity, etc. This can be utilised to modify or enhance the material properties, or as

4260-767: Was acquired by Borden Chemical of Columbus, Ohio, now 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-formaldehyde resins, which could be made in brighter colors than poly­oxy­benzyl­methylene­glycol­anhydride. 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. In 1927, beads, bangles, and earrings were produced by

4331-408: Was aggressively marketed as "the material of a thousand uses". A filing for a trademark featuring the letter B above the mathematical symbol for infinity was made August 25, 1925, and claimed the mark was in 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

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4402-467: Was also very important to the developing automobile industry. 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. Bakelite was also very commonly used in making molded grip panels on handguns, as furniture for submachine guns and machineguns, the classic Bakelite magazines for Kalashnikov rifles, as well as numerous knife handles and "scales" through

4473-560: Was formed in 1926. A new Bakelite factory opened in Tyseley , Birmingham, around 1928. It was the "heart of Bakelite production in the UK" until it closed in 1987. A factory to produce phenolic resins and precursors opened in Bound Brook, New Jersey , in 1931. In 1939, the companies were acquired by Union Carbide and Carbon Corporation . In 2005, German Bakelite manufacturer Bakelite AG

4544-514: Was most successful with wood and asbestos fibers, though asbestos was gradually abandoned by all manufacturers due to stricter environmental laws. Baekeland filed a substantial number of related patents. Bakelite, his "method of making insoluble products of phenol and formaldehyde", was filed on July 13, 1907, and granted on December 7, 1909. He also filed for patent protection in other countries, including Belgium, Canada, Denmark, Hungary, Japan, Mexico, Russia, and Spain. He announced his invention at

4615-531: Was one of the first plastic-like materials to be introduced into the modern world and was popular because it could be moulded and then hardened into any shape. Because of its electrical nonconductivity and heat-resistant properties, it became a great commercial success. It was used 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. The creation of

4686-699: Was producing enough material in the US to justify expansion. He formed the General Bakelite Company of Perth Amboy, New Jersey, as a U.S. company to manufacture and market his new industrial material, and made overseas connections to produce it in other countries. The Bakelite Company produced "transparent" cast resin (which did not include filler ) for a small market during the 1910s and 1920s. Blocks or rods of cast resin, also known as "artificial amber", were machined and carved to create items such as pipe stems , cigarette holders , and jewelry . However,

4757-417: Was soon used for non-conducting parts of telephones, radios, and other electrical devices, including bases and sockets for light bulbs and electron tubes (vacuum tubes), supports for any type of electrical components, automobile distributor caps, and other insulators. By 1912, it was being used to make billiard balls, since its elasticity and the sound it made were similar to ivory. During World War I, Bakelite

4828-414: Was to find a replacement for shellac , a material in limited supply because it was made naturally from the secretion of lac insects (specifically Kerria lacca ). He produced a soluble phenol-formaldehyde shellac called Novolak , but it was not a market success, even though it is still used to this day (e.g., as a photoresist ). He then began experimenting on strengthening wood by impregnating it with

4899-401: Was used in solid-body electric guitars . Performers such as Jerry Byrd loved the tone of Bakelite guitars but found them difficult to keep in tune. Charles Plimpton patented BAYKO in 1933 and rushed out his first construction sets for Christmas 1934. He called the toy Bayko Light Constructional Sets , the words "Bayko Light" being a pun on the word "Bakelite". During World War II, Bakelite

4970-572: Was used in a variety of wartime equipment including pilots' goggles and field telephones. It was also used for patriotic wartime jewelry. 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 . During World War II, Bakelite buttons were part of British uniforms. These included brown buttons for

5041-588: Was used widely, particularly in electrical systems. Important projects included the Liberty airplane engine , the wireless telephone and radio phone, and the use of micarta-bakelite propellers in the NBS-1 bomber and the DH-4B aeroplane . Bakelite's availability and ease and speed of molding helped to lower the costs and increase product availability so that telephones and radios became common household consumer goods. It

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