Chloe Zhang
Thermosetting plastics are polymers that become rigid when heated and do not soften when cooled. They are used in a wide range of applications, from electrical insulators to car bodies, due to their excellent strength attributes and heat-resistant properties. The first commercially available synthetic material, Celluloid, was invented in 1866 by John Wesley Hyatt. However, the first true thermosetting plastic was Bakelite, invented by Leo Baekeland in 1909. Baekeland was a Belgian chemist who developed the plastic by forming phenol and formaldehyde under high temperature and pressure.
| Characteristics | Values |
|---|---|
| Name of the first thermosetting plastic | Bakelite |
| Inventor | Leo Baekeland |
| Year of Invention | 1907 or 1909 |
| Country of Invention | United States |
| City of Invention | Yonkers, New York |
| Basis | Phenol-formaldehyde |
| Basis (other names) | Polyoxybenzylmethylenglycolanhydride, phenolic resin |
| Basis (other descriptions) | Condensation product of formaldehyde and phenol, formed under high temperature and pressure |
| Basis (other descriptions) | Condensation reaction of phenol with formaldehyde, with wood flour or asbestos fiber as a filler |
| Basis (other descriptions) | Hard, compact, insoluble, and infusible condensation products of phenols and formaldehyde |
| Basis (similar substances) | Catalin, Faturan, Crystalate, Galalith, Micarta |
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What You'll Learn
Bakelite: the first thermosetting plastic
Bakelite, the first thermosetting plastic, was invented by Leo Baekeland in 1907 and patented in 1909. Baekeland was a Belgian chemist who had moved to Yonkers, New York, where he invented the first plastic made from synthetic components.
Bakelite is a thermosetting phenol-formaldehyde resin, formed from a condensation reaction of phenol with formaldehyde. The result is a hard plastic material that does not soften when heated. This unique quality made it ideal for use in electrical insulators, radio and telephone casings, cookware handles, and irons. It was also used in diverse products such as kitchenware, jewellery, pipe stems, children's toys, and firearms.
The process of creating Bakelite involves combining phenol and formaldehyde under high pressure and heat. The curing process takes only a few minutes, and the resulting material can be moulded and hardened into any shape. This moulding process was advantageous because it was faster and produced a smooth surface that required less finishing. The efficiency of the process meant that millions of parts could be duplicated quickly and cheaply.
Bakelite played a significant role in the development of the modern plastics industry. It was one of the first plastic-like materials introduced to the world and became a commercial success due to its electrical non-conductivity and heat-resistant properties. The versatility and durability of Bakelite contributed to its popularity and impact on the market, with its applications extending beyond insulation to various consumer products.
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Belgian chemist Leo Baekeland
Leo Hendrik Baekeland was a Belgian chemist who invented the first thermosetting plastic, known as Bakelite. Baekeland was born in Ghent, Belgium, on November 14, 1863, the son of a cobbler, Charles Baekeland, and a housemaid, Rosalia Merchie. He had an early passion for photography and developing pictures, which sparked his interest in chemistry. He graduated with honours from the Ghent Municipal Technical School and was awarded a scholarship by the City of Ghent to study chemistry at Ghent University, which he entered in 1880. After graduating, he was appointed Professor of Physics and Chemistry at the Government Higher Normal School in Bruges in 1887.
In 1891, Baekeland set up his own business as a consulting chemist. During this time, he developed Velox, a type of photographic printing paper that could be developed under artificial light. This invention was a commercial success, and in 1899, he sold it to the Eastman Kodak Company, reportedly for $750,000. With these funds, he moved to New York and established a laboratory and consultancy.
Baekeland then turned his attention to the field of synthetic resins, intending to capitalize on the growing recognition that many natural resins and fibres were polymeric. He experimented with the reactions of phenol and formaldehyde, eventually creating the first thermoset plastic in 1907 or 1909. This plastic, phenol-formaldehyde, was trade-named Bakelite. It was inexpensive, non-flammable, and versatile, marking the beginning of the modern plastics industry. As such, Baekeland has been dubbed the "Father of the Plastics Industry".
Bakelite offered the unique benefit of retaining its shape, even under heat and pressure. This property made it ideal for a wide range of applications, including electrical insulation for handles on cookware and irons, telephone earpieces, electrical housings, and connecting blocks. During World War II, Bakelite was a key ingredient in many weapons. Baekeland's contributions to chemistry were recognized through his election to the American Philosophical Society in 1935 and the United States National Academy of Sciences in 1936. He also served as president of the American Chemical Society in 1924.
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Phenol-formaldehyde
The properties of phenol-formaldehyde resins vary based on the ratio of phenol to formaldehyde and the type of catalyst used. These resins are known for their strength, versatility, and stability, making them valuable in various industries such as automotive, construction, and woodworking. They have been used in automotive components like brake pads and fuel pumps, as well as in the manufacturing of wood products. Additionally, phenol-formaldehyde resins exhibit good thermal insulation properties, making them suitable for tools and applications that must withstand high temperatures.
Novolacs (or novolaks) are a type of phenol-formaldehyde resin with a formaldehyde to phenol molar ratio of less than one. They require a curing agent or hardener, such as hexamethylenetetramine, to form a thermoset. On the other hand, resoles are phenol-formaldehyde resins with a formaldehyde to phenol ratio of greater than one. They cure without the need for a cross-linker, making them "one-step" resins.
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Synthetic substitute for shellac
The first thermosetting plastic was phenol-formaldehyde, trade-named Bakelite, invented by Dr. Leo Baekeland in 1909. Thermosetting plastics retain their strength and shape even when heated, making them suitable for the production of permanent components and large solid shapes.
Now, onto the topic of shellac and its synthetic substitutes. Shellac is a natural resin produced by insects called Laccifer lacca. After feeding on the sap of certain cultivated Oriental trees, the insects leave an exudation called "lac" on the twigs. This substance is scraped off, heated, and strained to create a natural resin with unique properties as a protective finish.
During World War II, supplies of shellac from India, its sole producer, were cut off. This prompted the search for synthetic substitutes, as shellac was critical for various industrial applications. One of the early synthetic substitutes for shellac was Zinlac, developed by chemist C. G. Harford. Zinlac is derived from corn and exhibits similar qualities to shellac, including quick-drying and elastic properties. However, Zinlac had limitations, such as its tendency to jell in solution.
Another synthetic substitute for shellac is described in a 1944 patent by John M. De Bell. This thermoplastic composition was designed to closely resemble the chemical and physical properties of shellac, particularly in the manufacture of sound-reproducing records. The composition includes a major proportion of petroleum hydrocarbon-insoluble pine wood resin, ethyl cellulose, and a plasticizing agent, such as natural glycerides like castor oil or coconut oil.
The development of synthetic substitutes for shellac continued, with other patents mentioning specific combinations of ingredients to create effective alternatives. These substitutes aimed to replicate shellac's unique properties for use in varnishes, coatings, and insulating compositions.
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Electrical insulators, radio and telephone casings
The first thermosetting plastic was Bakelite, a thermosetting phenol-formaldehyde resin, invented by Leo Baekeland in 1907 and patented in 1909. Baekeland was a Belgian chemist based in Yonkers, New York, who had previously developed the first commercially successful photographic paper.
Bakelite was the first plastic made from synthetic components and could be moulded and hardened into any shape. It was electrically non-conductive and heat-resistant, making it ideal for electrical insulators, radio and telephone casings, kitchenware, jewellery, pipe stems, children's toys, and firearms. Its smooth, polished surface meant that Bakelite objects required less finishing, and its quick curing time meant that millions of parts could be duplicated quickly and cheaply.
Bakelite was used extensively as an insulating material for handles on cookware and irons, and later found applications in telephone earpieces, electrical housings, and connecting blocks. It was also a key ingredient in many weapons used in World War II. During the 1940s and 1950s, plastic material development accelerated, with additional thermosets such as unsaturated polyesters and epoxies being introduced.
Thermosetting plastics have unique properties that make them suitable for a wide range of applications. For example, epoxies exhibit elasticity and exceptional chemical resistance, while phenolics are fairly simple to mould but are brittle and strong. The ability of thermosetting plastics to retain their strength and shape even when heated makes them ideal for electrical insulators and other applications requiring high heat resistance.
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Frequently asked questions
The first thermosetting plastic was invented by Leo Baekeland in 1907 and was patented in 1909.
The first thermosetting plastic was called Bakelite.
Bakelite is a thermosetting phenol-formaldehyde resin, formed from a condensation reaction of phenol with formaldehyde.
Bakelite was used extensively as an insulating material for handles on cookware and irons, electrical insulators, radio and telephone casings, and such diverse products as kitchenware, jewellery, pipe stems, children's toys, and firearms.
Bakelite was the first plastic made from synthetic components and was popular because it could be moulded and then hardened into any shape. Its electrical non-conductivity and heat-resistant properties made it a great commercial success.
