The Plastic That Shaped the Future

 

QUESTION: Recently I purchased a box of assorted costume jewelry at a flea market. What intrigued me was the variety of colorful plastic bracelets in the assortment. While these look like they’re made of regular plastic we know today, the dealer told me they were Bakelite. My grandfather once told me that Bakelite was the first plastic. He had an old radio that seemed to have a plastic case. At the time, I didn’t believe it because I thought plastic was a mid-20th century invention. What can you tell me about Bakelite? Who invented it and when?

ANSWER: Without knowing it, you’ve discovered a treasure of the early 20th century. Bakelite was a chemical miracle of the 20th century. It enabled manufacturers to make a variety of items—children’s toys, kitchenware, pipe stems, wall switches, appliance and cutlery handles, colorful radio cases, and yes, jewelry. Dubbed the “Material of a Thousand Uses” by the Bakelite Corporation, Bakelite was versatile and nonflammable.

Leo Baekeland developed this innovative form of plastic in his backyard laboratory in Yonkers, New York, between 1907 and 1909. He attempted to create a synthetic shellac when he discovered that phenol, or carbolic acid, and formaldehyde, when combined under certain conditions, resulted in a molasses-colored resin with unique and exceptional properties.

Once cured, the phenol formaldehyde resin could be ground into powder and mixed with a variety of fillers to create a molding compound that was practically indestructible. Slate dust, asbestos, wood flour and ground walnut shells were all used for this purpose, but because of their dark color, molded Bakelite was limited to shades of black, maroon and brown.

In1911, he founded the General Bakelite Company in Perth Amboy, New Jersey, which produced up to 200,000 tons of the plastic each year. Because it was resistant to heat, moisture, and chemicals, it became a component of the electrical industry. It also had excellent insulating properties, making it perfect for use in electrical insulators, switches, plugs and sockets. 

Making Bakelite was a multi-stage process. It began with the heating of phenol and formaldehyde in the presence of a catalyst such as hydrochloric acid, zinc chloride, or the base ammonia. This created a liquid condensation product, referred to as 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 when performed at standard atmospheric pressure, 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 around 300° F, he was able to suppress the foaming. The resulting substance was extremely hard and both infusible and insoluble. The range of colors available included black, brown, red, yellow, green, gray, blue, and blends of two or more of these. 

Bakelite came in various forms to suit varying needs, including clear material, for jewelry and smokers' articles, cement, used in sealing electric light bulbs in metal bases, varnishes, for impregnating electric coils, lacquers, for protecting the surface of hardware, and enamels, for giving resistive coating to industrial equipment. In addition, there was laminated Bakelite, used for silent gears and insulation; and molding material, used to form items of utility and beauty.

When Bakelite’s patent on phenol formaldehyde expired in 1927, other companies using the chemical came on the scene, including the American Catalin Corporation which pioneered a purified form of phenolic resin that did away with the dense fillers used in molded Bakelite. The company introduced casting resins in 20 different colors.

The Bakelite Corporation quickly developed its own phenolic resin, producing it in thousands of colors. In reality its recipes were exactly the same as American Catalin, except they experimented more with dye saturation and mixing colorants with clear resin to create mottled and swirled effects.

By the mid 1930s, several competitors had begun producing phenolics which forced the price of both Bakelite and Catalin down. One of these other companies, Fiberloid, introduced Opalon in lapis lazuli, mottled red, alabaster, onyx and mottled walnut, fabricated into board game pieces, jewelry, and umbrella and knife handles.

The introduction of electrical power gave rise to a wide range of labor-saving devices that utilized Bakelite and Catalin in one way or another. The modern appearance, durability and hygienic qualities of plastic made it superior to traditional substances.

Bakelite quickly replaced wood and metal in telephones, clock and barometer cases, as well as knobs and handles on small appliances like electric irons, toasters and cookware. Colorful Catalin cutlery handles and novelty napkin rings dressed up the table and brightened the kitchen.

In 1933 the Bakelite Corporation began to produce wood-tone radio cabinets of compression-molded phenolic resin. Thermosetting plastics resisted the heat generated by radio tubes, making Catalin ideal for radio cabinets. It wasn't long before colorful, modernistic Catalin radios began to make their appearance.

By 1936, various companies made two-thirds of all costume jewelry produced in the U.S. by fabricated molding and fabricating cast phenolic resin. The fabricating process, however, was labor-intensive and lengthy.

First, molds had to be made by dipping a steel master into molten lead. Once workers  assembled enough molds, others prepared phenolic resin and carefully poured it into each mold by hand. A technician carefully combined resins as casting occurred if special swirled or mottled colors were desired, the technician needed to carefully combine resins as they were being cast.

Once filled, workers wheeled the molds into a huge oven to be baked  at176 degrees F. until the resin cured. Curing time varied. Dark red and blue cured in three to four days while whites took six to eight days. Once the cast resin cured, workers removed it from the lead molds using air hammers. This always resulted in damaged molds. Other workers tossed the broken pieces back into the vat of molten lead to be melted down for reuse.

To make jewelry components, workers cut shaped or hollow phenolic rods into individual pieces, much like slicing a loaf of bread. Then they carved and machined by hand them for added adornment. Once they completed the decorative carving, they finished the pieces by tumbling or buffing on a polishing wheel.

Bakelite became a symbol of progress and modernity as the streamlined Art Moderne style overtook the chic style of Art Deco. The sharp-stepped sides of skyscrapers softened into curves, while boxy trains and automobiles became sleek, with fluid lines that created the illusion of speed and motion.

By the late 1930s, plastic moldings reflected the streamline design trends. Shiny surfaces, modernistic curves, waterfall fronts and facades, made to look like car grills, all found their way into jewelry, small home appliances and decorative household objects.

Perfectly suited to Bakelite and Catalin molds, the Art Moderne style enabled the resin to easily flow inside a curved mold. In addition, it was easier to mold, fabricate, and polish the resulting casts than the boxy, stepped sides and sharp corners of Art Deco designs.

Cast phenolic resins weren’t as durable as compression molded phenolic compounds because they shrank over time, often resulting in cracks. Catalin averaged a 4 percent shrinkage in the first 10 years. Cracks developed in radio cases because the parts were bolted to the housing, leading to stress as the plastic shrank.

Though companies produced Catalin in 20 opaque and translucent colors, engineers limited the color range because they felt all other dyes would cause instability in the plastic.

Unfortunately, Catalin reacted to ultraviolet light by converting to phenyl alcohol, which was brownish in color. That was why so many Catalin items are amber colored. The effect turned original white to butterscotch, bright blue into drab olive, green into butterscotch, and brilliant red marble into brown.

To read more articles on antiques, please visit the Antiques Articles section of my Web site.  And to stay up to the minute on antiques and collectibles, please join the over 30,000 readers by following my free online magazine, #TheAntiquesAlmanac. Learn more about "folk art" in the 2023 Winter Edition, online now. And to read daily posts about unique objects from the past and their histories, like the #Antiques and More Collection on Facebook.

Calling Mr. Watson

QUESTION: I have one of those large black rotary telephones. Are those collectible now that we have such advanced technology?

ANSWER: You might want to consider holding on to your black phone for a while as they and many 20th-century models are coming into their own as collectibles.

“Mr. Watson, I need you.” When Alexander Graham Bell, the Scottish-born American inventor, scientist, and teacher of the deaf who’s most noted for his invention of the telephone in 1876,  spoke those now famous words to his colleague during the first telephone call on March 10, 1876, he had no idea where that would lead us. Today, many people have smart phones that do just about everything except make a cup of fresh coffee, although I suspect they’ll soon offer an “app” for that, although national brand coffee shops now have apps to order and pay for coffee right from a smartphone.

But what about all the phones that came before the smart ones. The long-time standard Western Electric 302 black rotary phone, introduced in 1937, is probably the most well known. Some people have game rooms in their homes in which they install a working pay phone. These workhorses, once owned by AT&T, were meant to last a long time.

When people think of old telephones, however, they usually imagine the Western Electric 102 candlestick-type phone, which went into use in 1927. Today, you can purchase an original for a modest $469 at the TelephonyMusuem online.

In the 1930s, Western Electric produced 202 model with an oval base, and later a sleeker handset, now selling for $289. Both the 102 and 202 models required a ringer, which customers had to buy separately. The large rotary 302 phone was the first to house the ringer in the phone. It was made from metal until World War II and sells for $199, then from plastic, selling for $169, until the late 1950s. Western Electric stamped the date of production on the base of its phones, so it’s easy to tell the age of the unit.

One of the big problems in collecting old phones is that many of the more unique ones have been reproduced, in working order, of course. While the originals sell for as much as $500, the reproductions sell for half that. Vintage phones from the 1920s can sell for as much as $2,000. So it’s important to watch for reproductions being sold as originals, especially on auction sites like eBay.

And don’t forget the sleek and colorful Princess phone, introduced in 1959, and the Trimline phone with dial in the handset, dating from 1965. Both replaced the stodgy desk phones of the past. Rotary dials continued to be offered even after touch-tone came out because phone companies charged an extra fee for touch-tone service and many customers didn't want to pay for it. The hotter the color of a Princess phone, the higher its price. The more common colors—pink, red, peach, and black—in touch or rotary sell for about $200 each while green, beige, white, aqua and yellow command prices of $150 and up.. The most common Princess phone in ivory sells for no more than $119. Most of the Princess phones require a $30 transformer to light the dial.

Collecting old phones isn’t difficult, but like clocks, you can have just so many in your house.

To read more articles on antiques, please visit the Antiques Article section of my Web site.  And to stay up to the minute on antiques and collectibles, please join the other 18,000 readers by following my free online magazine, #TheAntiquesAlmanac. Learn more about western antiques in the special 2019 Spring Edition, "Down to the Sea in Ships," online now. And to read daily posts about unique objects from the past and their histories, like the #Antiques & More Collection on Facebook.

Promoting Through Time

QUESTION: I have an old clock with advertising for Jolly Tar Pastime Tobacco on it in raised letters. I’ve had the clock for a long time and never saw another one like it. Can you tell me anything about it?

ANSWER: You’re the lucky owner of a Baird advertising clock. You’ve no doubt seen pens and other items with printed advertising on them. But in the 1890s, a clock advertising a company was a novelty. Clocks promoted foods and beverages, household products, even medicines, such as Monells Teething Cordial for Children. They even advertised pet food like Clarke’s Patent Buffalo Meat Dog Cakes, endorsed by Queen Victoria, herself. Each clock says something different on it.

Born in Philadelphia in 1860, Edward Payson Baird went to work for the Seth Thomas Clock Company in 1879. In 1887, he left Seth Thomas to form his own company, the Baird Manufacturing Company, in Montreal, Canada,  to produce cases and doors for advertising clocks to house Seth Thomas movements. While he made his cases of pine or oak, he used papier-maché for the doors, with embossed letters around the clock face promoting the virtues of one product or another. Baird had numerous clients in the United States as well as in Canada and  Great Britain.

Baird used papier-maché for his clock doors because of the ready availability of wood pulp in Canada. By 1890, he moved his operation across the border to Plattsburgh, New York.  When economic circumstances forced him to close his Plattsburgh factory in 1896, Baird shifted his base of operations to Chicago, where he produced clocks with embossed, stamped tin advertisements. However, by that time interest in advertising clocks had begun to wane, so he concentrated his efforts on manufacturing parts for the fledgling telephone industry.

While some advertising brands, like Coca-Cola, are instantly recognizable and still exist today, many other products and brand names have long since disappeared. Baird clocks are the only clocks made from papier-maché that have advertising on them. Most resemble a figure 8. The top doors are 18 inches wide, while the bottom ones are 12 inches wide. While Baird clocks are 30½ long, Baird did make smaller 26-inch models. 

Baird also produced 18-inch-diameter gallery clocks. For the most part the dial on these clocks  measures 12 inches and the hands are straight, with a few exceptions. All Baird clocks have two doors unlike many other clocks produced at the time with only one door, giving access to the dial and pendulum.

A Baird clock in good working condition, with its original dial, glass, movement, and paint job, can sell for around $3,000. Some exceptional pieces sell for over twice that and higher. And well known brands, again like Coca-Cola, can sell for even more.

Telecommunications Relics

QUESTION: I recently purchased a box of glass insulators, like the kind used on telephone and electric poles. A couple of little white specks in the glass. I bought them because of their beautiful colors, but do these things have any value as a collectible? And just how were they used?

ANSWER: There’s nothing like the beauty of colored glass, especially when placed in a window where the sun can shine through it. Many people collect these glass electrical insulators for just that reason. But some, especially retired linemen, collect them because they’re a part of the history of telecommunications.

Ezra Cornell invented the insulator in 1844 as a means of protecting electrical wires front the elements and reducing the loss of current from the wire to the ground. As technology developed, power and telephone companies needed more insulators.

The earliest insulators had unthreaded pin holes. Because linemen simply pressed them onto a wooden pin, extending upwards from the crossarm of an electric pole, they didn't stay on very well since the wires contracted and expanded in the heat and cold. When Louis A. Cauvet improved the insulator by patenting the threaded pin hole type in 1865, he sold his invention to Brookfield Glass Company of  Brooklyn, which remained a major producer of insulators until 1922.

Though threaded pin holes helped insulators stay put, moisture still presented a problem since wet glass served as a conductor. In 1893, the Hemingray Company, another major manufacturer, obtained a patent for insulator "drip points." These bumps, which line the outside bottom rim of the insulator skirt,  helped prevent shorts by causing moisture to drip off. The earliest points were sharp but these were easily broken, leading to the manufacture of more rounded ones. Hemingray must have discovered that these really didn't work, since they eliminated them from later models. However, other companies continued to make insulators with drip points.

Porcelain insulators began to replace glass examples in the early 20th century, particularly on high voltage lines since glass insulators only worked on lines handling up to 60,000 volts.. By the late 1940s, only a few producers of glass insulators remained, by 1969, Kerr Manufacturing was the only company still making them.

Manufacturers produced glass Insulators in a variety of colors and types of glass. They used remnants of window or bottle glass for earlier ones. Most companies made insulators only as a sideline,  pressing them out of whatever kind of glass happened to be available. Because of this, objects like nails, screws, coins, and bits of furnace brick would get mixed into the glass. Collectors call the little white furnace brick bits rocks. Some makers, like Hemingray, would cull out these blemished pieces, but others like Brookfield Company would just sell the blemished pieces along with the good ones.

The most common insulator colors are clear and light bluish-green or aqua. Other colors include sun-colored amethyst, green,  milk glass, royal blue, cobalt, amber and Carnival glass. The only color not made in glass is red, because red requires gold as a colorant. The most popular colors are royal blue and cobalt, with amethyst a close second. Insulator makers originally produced purple ones, ranging from  light lavender to deep amethyst, from clear glass. Manganese, used to clarify the glass, turned the glass purple after being exposed to the sun’s ultraviolet rays. After the start of World War I, manganese became scarce since it was needed for arms production. Manufacturers switched to selinium, which the sun turned to the color of wheat.

Common clear and aqua insulators sell for as little as a dollar each. But prices climb steadily for rare ones such as the Buzby or the Twin Pin. Aqua ones made by the Jeffrey Manufacturing Company can sell for as much as $125 each while a threadless Canadian insulator, also known as a snow cone, can sell for about $2,000.

For more information on glass insulators, go to www.insulators.info/.