Others nearly beat him to it. As early as 1872, German chemist Adolf von Baeyer was investigating the recalcitrant residue that gathered in the bottom of glassware that had been host to reactions between phenol (a turpentine-like solvent distilled from coal tar, which the gas-lighting industry produced in bulk) and formaldehyde (an embalming fluid distilled from wood alcohol). Von Baeyer set his sights on new synthetic dyes, however, not insulators. To him, the ugly, insoluble gunk in his glassware was a sign of a dead end.

To Baekeland and others aiming to find commercial opportunities in the nascent electrical industry, that gunk was a signpost pointing toward something great. The challenge for Baekeland and his rivals was to find some set of conditions — some slippery ratio of ingredients and heat and pressure — that would yield a more workable, shellac-like substance. Ideally it would be something that would dissolve in solvents to make insulating varnishes and yet be as moldable as rubber.

Starting around 1904, Baekeland and an assistant began their search. Three years later, after filling laboratory books with page after page of failed experiments, Baekeland finally developed a material that he dubbed in his notebooks "Bakelite." The key turned out to be his "bakelizer," a heavy iron vessel that was part pressure cooker and part basement boiler. With it, he was able to control the formaldehyde-phenol reaction with more finesse than had anyone before him.

Initial heating of the phenol and formaldehyde (in the presence of an acid or base to get the reaction going) produced a shellac-like liquid good for coating surfaces like a varnish. Further heating turned the liquid into a pasty, gummier goo. And when Baekeland put this stuff into the bakelizer, he was rewarded with a hard, translucent, infinitely moldable substance. In a word: plastic.

He filed patent applications and soon began leaking word of his invention to other chemists. In 1909 Baekeland unveiled the world's first fully synthetic plastic at a meeting of the New York chapter of the American Chemical Society. Would-be customers discovered it could be fashioned into molded insulation, valve parts, pipe stems, billiard balls, knobs, buttons, knife handles and all manner of items.

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Sept. 22, 1924

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