The History of Plastics in 60 minutes

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					A History of Plastics

from Charles the First

 to Charles the Third

  Geoff Pritchard
       Worcester U3A
            Raw materials for plastics
      Before 1900:                            plants
     1880-1945:                              coal; milk; plants
      In modern times:                       salt; oil and natural gas
21st Century: castor beans,
palm oil, sugar, cotton,
corn, tapioca, algae,
biomass
Note: the rise in the price of sugar raised the
UN FAO Food Price Index to 234 in June 2011,
near to its record level of 239


Castor oil beans make starting materials for carbon-neutral
“nylons” for vehicle parts. (CO2 is absorbed during bean growth)
               Sir Robert Hooke, 1635--1703
Not popular. No portraits survive.
Disfigured by smallpox as a child; orphan; father committed
suicide when he was 13; difficult temperament, enemies (such
as Isaac Newton) prevented recognition as an English
Leonardo da Vinci.
Inventor of:
 the iris diaphragm in cameras, the universal joint in vehicles,
the balance wheel in watches, etc.
First to use the word 'cell' in the context of biology
Author of the first book on microscopy

Surveyor of the City of London after the Great Fire.
Architect, astronomer; deputy to Sir Christopher Wren.
Known today for “Hooke’s Law” and the concept of extrusion.
PART ONE: Natural Plastics
        (resins)
Flowers, foliage and fruit
of the Isonandra Gutta
Percha Tree




 A resin is obtained by
 evaporating and coagulating the milk
 from the gutta percha tree trunk. It
 can be shaped in boiling water.
                             http://www.bouncing-balls.com/serendipity/gutta.htm
 Gutta percha---a natural plastic or
 “resin”          (Tradescantia was
                                                    named after his dad)
                         John Tradescant (1608-62) the younger
                         (head gardener to Queen Henrietta Maria
                         at Greenwich, 1638-42) obtained Mazer
                         wood, via a merchant, from Singapore
                         (1656).
                         Used for knife handles (1843)*, medical
                         devices, jewellery; to insulate undersea
                         cables (1847 till 1940s).
First gutta golf ball in 1840’s by Rev. Dr.
Paterson. (Previously, wood or leather stuffed with
feathers). Much cheaper, making golf more popular.
1845 Lagrénée returned to France with some gutta percha which he named “gum plastic”.
Synthetic gutta percha developed at
Dunlop for golf ball covers, 1960-2.
                                Stirrer shaft



                                           One litre
                                           Pyrex
                                           reaction
                                           vessel
            Gutta percha is trans 1, 4 polyisoprene whereas
            natural rubber is cis 1, 4 polyisoprene
MARCH 29,1851


 SEE RIGHT
HAND COLUMN
From:

Notes and Queries
In 1839 a German apothecary, Eduard Simon,
distilled an oil from the resin of the Sweetgum tree,
and named it "styrol". Over a few days it formed a
jelly, which he called “styrol oxide”. It was
actually poor quality polystyrene and not an oxide.

It’s not recognised as the first fully man-made
plastic; usable polystyrene only came in 1933!
                    Trunk of rubber tree,
                    Hevea brasiliensis,
                    with cup for collecting “milk”




The rubber is coagulated, dried and “over-cooked”
with sulphur to form ebonite for gramophone
records, bowls, castors, (smoking) pipes.
                  PLASTICS FROM COWS!
                       Casein plastics
          (1899) (“The most beautiful of all plastics”)
                                              Inventors:
                                              Krisch & Spitteler
                                              (Germany)




                     “Artificial horn”

A protein is separated from milk by the enzyme rennin. It is
moulded to shape under heat and pressure, and hardened by soaking
in formalin (health hazard!). Casein products are machined from
sheet, rod, or tube. Now confined mostly to buttons in New Zealand
Alexander Parkes     1813 - 1890
    Manager of the metal casting
    department at Elkington,
    Mason & Co. in Birmingham.



        1846 Parkes patented a mixture
        of natural rubber with gutta
          percha. The world‟s first
        blended and toughened plastic?
1856: The world’s first semi-synthetic
              plastic
        Invented in Birmingham


   Parkes took out over 80 patents and made the
   world’s first artificial plastic, cellulose nitrate.
   He called it “Parkesine,” [shown at the
   International Exhibition in London in 1862].

   Awarded a medal, made no profit.
  The American printer / inventor John Wesley
  Hyatt was asked by Phelan & Collander
  (manufacturers of billiard balls) to find a
  substitute for ivory (elephants were scarce).

  .




Hyatt made cellulose nitrate, called it “Celluloid”.
His “stuffing machine” (1872) was a forerunner
of modern injection moulding machines
Four stages of celluloid production and moulding
           (Celluloid Manufacturing Co., Albany, NY, USA)
                                     1
                              Ethanol, dye
Cotton + Nitric Acid, Sulphuric Acid           Nitrocellulose
                                Heat, pressure,
                                reaction vessel
                                                    Clean-up,
                                                    ethanol
                                                    removal 2

                       4                 3
    Moulded                                Pure Celluloid with
    article                      Powdering added camphor
                   “Stuffing               to adjust softness
                    machine” (1872)
                    19th Century Celluloid Uses
Dental plates (1871); knife handles; toys; washable collars
and cuffs; billiard balls, buttons, brooches,
dolls, folding toothpicks, combs, paperweights, thimbles,
shoe-horns, table tennis balls, etc.
Celluloid strips were coated with a photosensitive gelatin emulsion
and used in early motion pictures (1880s) ---big fire problem!
Later replaced by cellulose acetate or polyester .


                                              Pen




          Celluloid Figurines
         PART TWO: MAN-MADE
              PLASTICS
Phenol + Formaldehyde  P-F resin + water
                         Dr Leo Baekeland
                         (Belgian) made P-F
                         resins; Founded
                         General Bakelite Co. in
                         1910 in USA
 Bayer (Germany) and Luft (Austria) had already
 made similar resins, but failed to commercialise them.
          Bakelite Companies.
James Swinburne formed Fireproof Celluloid
   Syndicate Ltd in 1904 to investigate the P-F
   insulating resins shown him by Luft of Austria. He
   failed to make insulator mouldings, but made a
   hard lacquer, more durable than shellac, and used
   it for coating brass to prevent tarnishing - (brass
   bedsteads were fashionable and made in
   Birmingham).
In 1910 he formed the Damard Lacquer Co. in a
   lean-to shed in Birmingham. Successful. Demand
   rose. Patent struggles with Baekeland.
BAKELITE Ltd was formed in 1927 to
exploit Baekeland’s patents in the UK by
merging:
Damard Lacquer Co.,
Baekeland Inc.,
Mouldensite Ltd (a leading moulding
company) and
Redmanol Ltd (the UK arm of an American
sales company)
      PVC was discovered in 1912 by Fritz
          Klatte, a German chemist.
   • Klatte reacted acetylene with hydrochloric
     acid to produce vinyl chloride. Thinking
     he'd failed, he put it on a shelf, where it
     went solid (formed PVC). He
    patented it in Germany. His company never
     did anything with it.

Ten years later, the patent expired. 1926, Waldo Semon,
American chemist with B.F.Goodrich, “discovered” PVC,
without knowledge of Klatte's discovery. He showed it to his boss,
who patented it in America. They thought it would make good
shower curtains.
The waterproof material soon found more creative uses, and
Goodrich made a fortune. Klatte never saw a penny.
PVC wire and cable jacketing has much better
durability than natural rubber. Less re-wiring!
                               It‟s also used
                               for pipe, buildings,
                               shoes, etc, etc




                               “Pay with plastic”
PVC Extrusions ---continuous “profiles”
such as gutters, hose, sheet, curtain rails,
conveyer belts for mining, window frames.




                                    PVC window
                                    frames were
                                    made on a
                                    large-scale in
                                    the early 1970s
                                    in Germany
                     Recorded music
 1880s Shellac used for records by Emil Berliner. First
 to use discs (rather than “phonograph” cylinders)
 despite earlier work by Edison, Bell and Cros. Even
 with cotton reinforcement it was brittle, but it could
 reproduce fine detail. Other companies used ebonite.


78 rpm was standard by late 1920s.
1952 PVC (“vinyl”). Known as
“unbreakable” because shellac resin cracked so easily.
                                     Others say Billy Joel‟s 52nd St, made
 Abba’s song “The Visitors” was      in Japan; or Beethoven‟s 9th, others
 the first commercial CD, in 1982.   say “Born in the USA”
                                     1982 is probably right.
 Made of polycarbonate.
     Polythene (“Polyethylene”)
• invented by Fawcett and Gibson (ICI)
  1933, production 1 Sept 1939;
• first use -- military radar (WW2)
• 6 different types later invented
Postwar: shopping bags,
wire insulation, packaging,
(failed) washing-up bowls


Later: stiffer type made, used for Fairy
Liquid bottles; swing-top bins; pipes
                “Dyneema” polyethylene
                has extra long molecules
          Fishing line


21st Century
a rmoured vehicles
         Rapid development
• Unsaturated polyesters (“fibre glass
  boats”) 1940s and 1950s

• Epoxy resins (“Araldite” etc) 1939

• Nylons; saturated polyester (“polyester-
  cotton shirts”) 1930s; (first textiles, then
  plastics)
          William H Carothers
Started as a junior accountant,
then chemistry student, then head of
college dept.,
Worked at DuPont

Invented Neoprene rubber,
Polyester textiles, (1930s)
(Dacron etc)
Invented nylon,             Committed
                           suicide at age 41.
Nylon is used for gears, low voltage
switchgear (top left); fishing lines,
under-bonnet car parts, toothbrushes;
but was invented as a textile.



           Semi-finished nylon products
           Bottom left)
Polypropylene (invented 1954)
         is versatile

 Stackable chairs

 Drinking water bottles (not huge ones)
 Banknotes
 Rope
 Vehicle parts
 Garden membranes for weed control
Polycarbonate (1953) is tough and
can be transparent…
discovered by Daniel Fox at GE (Lexan) and by
Hermann Schnell at Bayer (Makrolon) (both in 1953)
Uses: riot shields, visors, greenhouses,
conservatories, lenses, CDs, DVDs,
headlamp glasses...
30% of all US spectacle lenses are made of
polycarbonate, because of lawsuits about
eye injuries from lenses breaking
.


                                                     Polycarbonate
                                                     for long riot
     American football                               shields and jet fighter
     helmet                                          cockpit canopies
                        Australian-designed
                        polycarbonate beer
                        glass




In 2009, the UK Home Office says that glass beer
mugs and bottles cost the NHS and police
£100 million a year through 87,000 reported injuries
Basic injection moulding machine for making
thermoplastic articles (from combs to chairs) A
screw was first used instead of a ram in 1946.
Close-up of a mould for making paper clips
       SOME APPLICATIONS
•   Vehicles
•   Packaging
•   Medical
•   Aircraft
•   Electronic
•   Solar energy
                   Some mouldings for road transport




                                               Air distributor
       Air ducts




Windscreen washer                                      Electric
                        Elbows, ducts and connectors
tank                                                   Bicycle
Toyota Prius (August 2009) uses plastics from plants
e.g. seat cushion foam, cowl side trim, inner and outer scuff
plates. Special Prius “A” for Japan uses air conditioning outlet
made from sugar. Other raw materials: polylactic acid from
starch, polyester, kenaf fibre, and polyols from castor oil.
    NEXT :POLYCARBONATE
    CAR WINDOWS!
Polycarbonate glazing is 50% lighter than glass
and has high impact resistance.
Suppliers claim a weight reduction of more than
20kg (50%) is possible when replacing all glass
windows (except the windshield) in a minivan.
Vehicle manufacturers can now try 3D-shaped
windows and new opening mechanisms.

Polycarbonate can now be made from carbon dioxide (and propylene oxide) instead of the hazardous use of phosgene
reacted with bisphenol A. The last-named chemical is under suspicion as a health hazard to foetuses and children
            Lithium ion batteries
• A separator is a plastic film (often specially
  modified polypropylene, or a polyimide)
  preventing the electrodes from touching, but
  letting lithium ions pass between them to allow
  the charge and discharge of the battery.
• A hybrid car has between 50 and 70
   batteries.
• plug-in hybrids--
  80 to 200
• fully electric cars
  at least 150.
   SUPERBUS MADE IN AN OVEN




This 15 metre long, Dutch-made battery-powered
bus –with gull-wing doors – is made from a carbon
fibre reinforced plastic chassis, glass reinforced
polypropylene bodywork, and polycarbonate
windows.
        THE PACKAGING INDUSTRY
                 SAYS:
Food packaging prolongs food life,
saves more than 25% food
from the waste bin. Plastic bottles save
on fuel, don’t break, and can be
recycled. Plastic packaging uses only
2% of all oil produced.


                                                               Collapsible
                                                               water bottle

Packaging is high–tech (multi-layered, can incorporate anti-piracy
watermarks for designer label goods, exclude oxygen, retain
moisture, stop meat discoloration, control CO2 access)
This food packaging by Linpac won a
European prize in 2009 for products containing over
50% recycled plastics
         MEDICAL PLASTICS
•   Tubing; IV accessories; blood bags      Papworth.

•
                                            900 of these
     Syringes; catheters                    worldwide



•   Implants
•   Temporary heart
•   Radiation shielding (instead of lead)
•   blood glucose meters; pumps; drug
    packaging
Note: plastic components can incorporate
antimicrobial additives (biocides) to combat
infection
 Only a few reinforced plastics parts shown here

                        Main-wing box                   Rear fuselage


Engine cowlings



                                              Cabin floor
    Galleys and
                                        Centre wing box
    lavatories
                                         Aileron (fibreglass)




  50% reinforced plastic
  (CFRP) so 20% less fuel   Boeing 787 Dreamliner
                              (Based on Flight International drawing)
                Clever Stuff
  • Space suits; Moon rover vehicles
  • Electrically conducting plastics
  • Electronic paper
  • “Smart” materials change colour in response
    to pressure, temperature, light, “remember”
    their previous shape and go back to it;
  • blood clot warning devices for air travellers;
    Heal any scratches by themselves*
(*An additive is used:--short polymer molecules
 containing zinc or lanthanum ions; it melts and
repairs the scratch in 1 minute under UV light,
provided the sample is thin enough)
 When Charles 3 is king: cheap solar energy?
     Edited quotes from researchers at Sheffield University, July 2011

“Ultra-cheap solar energy panels will one day be made on
a large scale. Rather than using complex and expensive
fabrication methods to create a specific semiconductor
nanostructure, high-volume printing will produce nano-
scale (60nm) polymer films of solar cells to make solar
panels."


"In 2 hours, enough energy from sunlight falls on the Earth
to satisfy the energy needs of its population for a whole
year, but we need cheap and efficient solar cells that can
cover huge areas to move us into a new age of renewable
energy.”
    LAST SECTION:

    SOME RECENT
    ENVIRONMENTAL ISSUES

  Most plastics can be recycled (even PVC!)
  but to be economic, different types should not
  be mixed up


Conversion to chemicals or fuel oil can be
more economic than simply re-shaping
Recycling
bottles




•Detergent, other cleaning fluids, shampoos,
pills, soft drinks --REMOVE LIDS FIRST
Recycling one plastic bottle can save enough energy
to light a 60W bulb for 6 hours
This boat was made from 16,000 recycled
PET bottles, to sail from San Francisco to Sydney.




                                     Recycled polyethylene walkway in
                                     Bracknell. The Domesday Book
                                     copse is low-lying and prone to
                                     flooding; so a wooden structure
                                     would have quickly rotted
     Courtesy of Tech Wood




This building is made of 70% waste sawdust
and 30% resin (such as polyethylene)
A UK Environment Agency document,
Life Cycle Assessment of Supermarket Carrier
Bags, asserts that polythene bags have
less impact on the environment than many
supposedly „green‟ alternatives;
the so-called single use plastic bag is around 200
times less damaging than multi-use cotton bags.

Feb 2011
                                Some biodegradable bags generate methane
                                rapidly during landfill
The UK Environment Agency (EA) has temporarily withdrawn its report while a legal query is resolved.
The report shows that re-use of bags rather than the material of which
they are made per se is the critical factor in reducing environmental impact. A cotton bag would have to be used at least 131
times to ensure that it has a lower global warming potential than a conventional “single use” lightweight HDPE carrier
bag that is not reused. Paper and compostable bioplastic bags also show higher global warming potential than the
conventional plastic bag. US students have identified polyurethane-eating organisms from the Amazon area.
The oceans have big “islands” of plastic rubbish
delivered to a central point by converging ocean currents


                                                                       According to the Germans, 80% of all
                                                                       marine waste reaches
                                                                        the sea from the land because of poor
                                                                       waste management. Germany already
                                                                       recovers 97% of its plastic waste.




 The Pacific one was once said to be 14 times the size of
 Holland, or twice that of Texas
 Other oceanographers disagree; they say if you just measure the area of the plastic, rather than
 the area affected by merging currents, it is a small fraction of the state of Texas, say 1% .
 A 22 year study has found no increase in size over that time.
Whim Architecture has proposed making an island
the size of Hawaii from Pacific ocean plastic waste,
to create a floating home for 500,000 people,
powered by solar energy and wave motion.
 Electrolux has launched a “Vac from the sea”
 initiative to suck waste out of the ocean to use it to
 make sustainable vacuum cleaners.
2 of the first 5 vacuum cleaners!!




                         The European Union
      Recycled plastic   offers fishermen
      “reefs” protect    cash for catching
      Dubai coast from   plastic rubbish
      erosion            instead of fish!
 What does scampi
 have in its stomach?
 Four fifths of them
 have plastic




 ----Researchers from London and Aberdeen Universities
 wrote in the Marine Pollution Bulletin, 2011:--


“The results of our study clearly show that scampi in
the Clyde (estuary) are consuming plastics and that one
of the sources of this plastic is that used by the scampi
fishery itself.” (that is, the nets!)
        THE END!



THANKS FOR STAYING AWAKE!

				
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