Synthetic resins and their raw materials

Chapter V: Part 5

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[1] Specified refractive degree.

NOTE.—The values for the properties in this table are based upon
maximum and minimum figures submitted to Modern Plastics by a
number of manufacturers of each type of material. Differences in
test procedures and sizes of test specimens may lead to erroneous
conclusions in some cases if direct comparisons are attempted.
Special grades of materials are often available which excel in
one particular property.

Source: Modern Plastics, vol. 15, no. 2, opp. p. 120. October
1937.

TABLE 18.—_Synthetic resins and other plastics: Molding properties_

[1] Positive and injection 0.002-0.003; semipositive 0.005-0.007;
flash 0.008-0.009.

Source: Modern Plastics, vol. 15, No. 2, opp. p. 120. October
1937.

Table 17 lists the properties which affect appearance and gives in addition to the color range, the clarity, material, the burning rate, the effect of age and sunlight, the refractive index, and the machining quality of each synthetic resin.

Table 18 lists molding properties of synthetic resins. Of special interest are the possibilities of using a resin in injection molding. The thermoplastic resins and plastics (see softening point in table 20) are generally preferred to the thermosetting materials for injection molding because they permit the reuse of material otherwise wasted.

Table 19 lists the strength properties of the synthetic resins; table 20 the heat properties; table 21 the electrical properties; and table 22 the resistance to acids, alkalies, and solvents. All of these qualities are important in some uses and each quality may be paramount in a few. Each material has its limitations and its special advantages and the consuming industry must choose the one best suited to its purposes. The tie-up between specific properties and particular uses is exemplified by vinyl resins, which because of their great elasticity at low temperatures, are used in safety glass, and by the polystyrene resins, which because of their electrical properties at high frequencies, are used in laminated electrical parts. As production of the various resins increases new uses will probably be found for most of them.

TABLE 19.—_Synthetic resins and other plastics: Strength properties_

-------------------------------+--------------+------------+-------------
Type | Tensile | Elongation | Modulus of
| strength | | elasticity
-------------------------------+--------------+------------+-------------
|_Pounds per | _Percent_ |_Pounds per
| square inch_ | | square inch_
Synthetic resins: | | | _× 10³_
Tar-acid—Formaldehyde: | | |
Molded, wood flour filler | 6,000-11,000 | | 10-15
Molded, mineral filler | 5,000-10,000 | | 10-45
Molded, fabric filler | 6,500- 8,000 | | 7-12
Laminated, paper base | 6,000-13,000 | | 5-20
Laminated, fabric base | 8,000-12,000 | | 5-15
Laminated, asbestos cloth | 9,000 | |
base | | |
Cast | 5,000-12,000 | | 5-15
Tar-acid—Furfural: | | |
Wood flour filler | 5,000-12,000 | | 10-25
Mineral filler | 4,000-12,000 | | 10-45
Fabric filler | 5,000-10,000 | | 7-12
Urea—Formaldehyde | 8,000-13,000 | | 16
Vinyl, unfilled | 8,000-10,000 | | 3.5-4.1
Vinyl, filled | 6,000-12,000 | | 3.5-8.5
Acrylate | 7,000- 9,000 | 1.0 | 6
Polystyrene | 5,500- 7,500 | 1.0 | 4.6-5.1
Other plastics: | | |
Shellac compound | 900- 2,000 | |
Cold molded | | |
Nonrefractory | | |
Refractory | | |
Rubber compounds: | | |
Chlorinated rubber | | |
Modified isomerized rubber | 4,300 | 0.013 | 4.7
Hard rubber | 4,000-10,000 | 8-15 | 5.3
Casein | 7,600 | | 5.1-5.7
Cellulose compounds: | | |
Ethyl cellulose | 2,000- 7,000 | | 2.8
Cellulose acetate sheet | 6,000-11,000 | 20-55 | 1-3
Cellulose acetate molding | 3,500-10,000 | 10-48 | 2-4
Cellulose nitrate | 5,000-10,000 | 10-40 | 2-4
-------------------------------+--------------+------------+-------------

-------------------------------+---------------+---------------
Type | Compressive | Flexural
| strength | strength
-------------------------------+---------------+---------------
| _Pounds per | _Pounds per
| square inch_ | square inch_
Synthetic resins: | |
Tar-acid—Formaldehyde: | |
Molded, wood flour filler | 16,000-36,000 | 8,000-15,000
Molded, mineral filler | 18,000-36,000 | 8,000-20,000
Molded, fabric filler | 20,000-32,000 | 10,000-13,000
Laminated, paper base | 20,060-40,000 | 13,000-20,000
Laminated, fabric base | 20,000-44,000 | 13,000-20,000
Laminated, asbestos cloth | 18,000-40,000 | 17,000
base | |
Cast | 15,000-30,000 |
Tar-acid—Furfural: | |
Wood flour filler | 28,000-36,000 | 10,000-16,000
Mineral filler | 24,000-36,000 | 8,000-14,000
Fabric filler | 26,000-30,000 | 10,000-16,000
Urea—Formaldehyde | 24,000-35,000 | 13,000-15,000
Vinyl, unfilled | | 10,000-13,000
Vinyl, filled | |
Acrylate | 8,000 | 15,000-17,000
Polystyrene | 13,000-13,500 | 6,500- 8,000
Other plastics: | |
Shellac compound | |
Cold molded | 6,000-15,000 | 5,300- 7,500
Nonrefractory |} 16,000 | 6,000
Refractory |} |
Rubber compounds: | |
Chlorinated rubber | |
Modified isomerized rubber | 8,500-11,000 | 7,000- 9,000
Hard rubber | 8,000-12,000 |
Casein | |
Cellulose compounds: | |
Ethyl cellulose | |
Cellulose acetate sheet | 4,000-16,000 |
Cellulose acetate molding | 11,000-16,000 | 5,200- 8,800
Cellulose nitrate | |
-------------------------------+---------------+---------------

[1] ASTM D256-34T. C = Charpy; I = izod; N = notched; U =
unnotched.

[2] 2.5 mm ball; 25 kg. load unless otherwise noted.

[3] 50 kg. load.

[4] 10 mm. ball; 500 kg. load.

[5] Shore.

[6] 10 kg. load.

Source: Modern Plastics, vol. 15, No. 2, opp. p. 120; October
1937.

TABLE 20.—_Synthetic resins and other plastics: Heat properties_

-----------------------------------+-----------+------------+-----------
| Softening | Distortion |
| point | under heat |
+-----------+------------+
Type | | |
| | | Tendency
| °F. | °F. | to cold
| | | flow
| | |
-----------------------------------+-----------+------------+-----------
Synthetic resins: | | |
Tar-acid—Formaldehyde: | | |
Molded, wood flour filler | None | 240-285 | None.
Molded, mineral filler | do. | | Do.
Molded, fabric filler | do. | | Do.
Laminated, paper base | do. | 320 | Do.
Laminated, fabric base | do. | | Do.
Laminated, asbestos cloth base | do. | | Do.
Cast | | |
Tar-acid—Furfural: | | |
Wood flour filler | Chars 450 | 268-288 | Do.
Mineral filler | Chars 550 | 277-297 | Do.
Fabric filler | Chars 400 | | Do.
Urea—Formaldehyde | None | 260 | Do.
Vinyl, unfilled | 130-160 | 140-150 | Slight.
Vinyl, filled | 130-160 | 140-158 | Do.
Acrylate | 170-235 | 158 | Do.
Styrol | 110-200 | 185 | Do.
Other plastics: | | |
Shellac compound | 150 | | Do.
Cold molded: | | |
Nonrefractory | | |
Refractory | | |
Rubber compounds: | | |
Chlorinated rubber | 175-230 | 140 | Do.
Modified isomerized rubber | 165-220 | 167-221 | Do.
Hard rubber | 150-190 | | Do.
Casein | | 200 |
Cellulose compounds: | | |
Ethyl cellulose | | 210-266 |
Cellulose acetate sheet | 140-230 | 122-212 | Do.
Cellulose acetate molding | 145-260 | 122-212 | Do.
Cellulose nitrate | 160-195 | |
-----------------------------------+-----------+------------+-----------

Source: Modern Plastics, vol. 15, No. 2, opp. p. 120. October 1937.

TABLE 21.—_Synthetic resins and other plastics: Electrical properties_

----------------------------------+-------------------------------
| Dielectric constant
+---------+----------+----------
Type | | |
|60 cycles|10³ cycles|10⁶ cycles
| | |
----------------------------------+---------+----------+----------
Synthetic resins: | | |
Tar-acid—Formaldehyde: | | |
Molded, wood flour filler |5-12 |4-8 |4.5-8
Molded, mineral filler |5-20 |4.5-20 |4.5-20
Molded, fabric filler |5-10 |4.5-6 |4.5-6
Laminated, paper base | | |4-6
Laminated, fabric base | | |4.5-7
Laminated, asbestos cloth base| | |
Cast |5-10 | |5-7
Tar-acid—Furfural: | | |
Wood flour filler | |4-8 |6-7.5
Mineral filler | |4.5-20 |5-18
Fabric filler | |4.5-6 |5-7.5
Urea—Formaldehyde |6.6 | |6
Vinyl, unfilled | | |4
Vinyl, filled | |4.7 |4
Acrylate |4-6 | |2.8
Polystyrene |2.6 |2.65 |2.7
Other plastics: | | |
Shellac compound | | |
Cold molded: | | |
Nonrefractory |15 | |6
Refractory | | |
Rubber compounds: | | |
Chlorinated rubber |ca. 3 | |
Modified isomerized rubber |2.7 |2.68 |
Hard rubber |2.8 | |3
Casein | | |6.15-6.8
Cellulose compounds: | | |
Ethyl cellulose | |3.72 |
Cellulose acetate sheet |5.1-7.5 | |4.2-5.3
Cellulose acetate molding |5.8-6.0 | |4.4-4.6
Cellulose nitrate |6.7-7.3 | |6.15
----------------------------------+---------+----------+----------

----------------------------------+----------------------------------
| Power factor
+-----------+----------+-----------
Type | | |
| 60 cycles |10³ cycles|10⁶ cycles
| | |
----------------------------------+-----------+----------+-----------
Synthetic resins: | | |
Tar-acid—Formaldehyde: | | |
Molded, wood flour filler |0.04-0.30 |0.04-0.15 |0.035-0.1
Molded, mineral filler |0.10-0.30 |0.10-0.15 |0.005-0.1
Molded, fabric filler |0.08-0.30 |0.08-0.20 |0.04-0.1
Laminated, paper base | | |0.02-0.05
Laminated, fabric base | | |0.02-0.08
Laminated, asbestos cloth base| | |
Cast |0.025-0.20 |0.005-0.08|0.01-0.045
Tar-acid—Furfural: | | |
Wood flour filler | |0.04-0.15 |0.035-0.1
Mineral filler | |0.1-0.15 |0.04-0.1
Fabric filler | |0.08-0.20 |0.035-0.1
Urea—Formaldehyde |0.034 | |0.01-0.03
Vinyl, unfilled | |0.0143 |0.0175
Vinyl, filled | |0.02-0.15 |0.02-0.065
Acrylate |0.06-0.08 | |0.02
Polystyrene |0.0003 |0.0001 |0.0001
Other plastics: | | |
Shellac compound | | |
Cold molded: | | |
Nonrefractory |0.20 | |0.07
Refractory | | |
Rubber compounds: | | |
Chlorinated rubber |0.003 | |
Modified isomerized rubber |0.006 | |0.0016
Hard rubber | | |0.003-0.008
Casein | | |0.052
Cellulose compounds: | | |
Ethyl cellulose | |0.011 |
Cellulose acetate sheet |0.025-0.07 | |0.038-0.091
Cellulose acetate molding |0.042-0.058| |0.038-0.042
Cellulose nitrate |0.062-0.144| |0.074-0.097
----------------------------------+-----------+----------+-----------

Source: Modern Plastics, vol. 15, No. 2, opp. p. 120. October 1937.

TABLE 22.—_Synthetic resins and other plastics: Specific gravity, specific volume, and resistance to other substances_

------------------------------+---------+--------------+-----------
| | |Water
Type |Specific | Specific |absorption,
| gravity | volume |immersion
| | |24 hours[1]
------------------------------+---------+--------------+-----------
Synthetic resins: | |_Cubic inches |
Tar-acid—Formaldehyde: | | per pound_ |
Molded, wood flour filler |1.34-1.52| 20.7-18.2 |0.2-0.6
Molded, mineral filler |1.70-2.09| 16.4-13.3 |0.01-0.3
Molded, fabric filler |1.37-1.40| 20.2-19.8 |1.0-1.3
Laminated, paper base |1.34-1.55| 20.7-17.8 |0.5-9.0
Laminated, fabric base |1.34-1.55| 20.7-17.8 |0.5-9.0
Laminated, asbestos cloth |1.6-1.65 | 17.3-16.8 |0.5
base | | |
Cast |1.27-1.32| 21.8-20.0 |0.01-0.5
Tar-acid—Furfural: | | |
Wood flour filler |1.3-1.4 | 21.3-19.8 |0.2-0.6
Mineral filler |1.6-2.0 | 17.3-13.9 |0.01-0.15
Fabric filler |1.3-1.4 | 21.3-19.8 |0.8-1.4
Urea—Formaldehyde |1.48-1.50| 18.7-16.5 |1-2
Vinyl, unfilled |1.34-1.36| 20.7-20.4 |0.05-0.15
Vinyl, filled |1.35-2.5 | 20.5-11.1 |0.2-4.0
Acrylate |1.18 | 23.3 |0.3
Polystyrene |1.05-1.07| 26.3-25.8 |0
Other plastics: | | |
Shellac compound |1.1-2.7 | 25.2-10.3 |
Cold molded: | | |
Nonrefractory |1.98-2.0 | 14.0-13.9 |1.5
Refractory |2.2 | 12.6 |0.5-15
Rubber compounds: | | |
Chlorinated rubber |1.5 | 18.5 |0.1-0.3
Modified isomerized rubber|1.06 | 26.1 |0.02
Hard rubber |1.12-1.8 | 24.7-15.4 |0.02
Casein |1.35 | 20.5 |3-7
Cellulose compounds: | | |
Ethyl cellulose |1.14 | 24.3 |[6]1.25
Cellulose acetate sheet |1.27-1.37| 21.8-20.2 |1.5-3.0
Cellulose acetate molding |1.27-1.63| 21.8-17.0 |1.4-2.8
Cellulose nitrate |1.35-1.60| 20.5-17.3 |1.0-3.0
------------------------------+---------+--------------+-----------

[1] ASTM D48-33.

[2] Decomposed by oxidizing acids; reducing and organic acids no
effect.

[3] On bleed-proof materials.

[4] Resists alcohols, aliphatic hydrocarbons, and oils. Soluble
in ketones and esters; swells in aromatic hydrocarbons.

[5] Soluble in ketones, esters, and aromatic hydrocarbons.

[6] 48 hours.

[7] Soluble in ketones and esters; softened by alcohols; little
affected by hydrocarbons.

NOTE.—The values for the properties in this table are based upon
maximum and minimum figures submitted to Modern Plastics by a
number of manufacturers of each type of material. Differences in
test procedure and sizes of test specimens may lead to erroneous
conclusions in some cases if direct comparisons are attempted.
Special grades of materials are often available which excel in
one particular property.

Source: Modern Plastics, vol. 15, No. 2, opp. p. 120. October
1937.

15. SYNTHETIC RESINS IN OTHER COUNTRIES

Large-scale production of synthetic resins is confined principally to the United States, Germany, and Great Britain. There is small production in many other countries, of which the most important are France, Italy, Czechoslovakia, Canada, and Japan.

In 1934 the world output was estimated at 135 million pounds, of which the United States produced about 44 percent, Germany 26 percent, and Great Britain 24 percent. In 1937 world output was estimated at 360 million pounds, the United States’ share of the total being almost 50 percent, followed by 27 percent for Germany, 20 percent for Great Britain, and the remaining 3 percent scattered.

European estimates indicate that about 40 percent of the output goes into surface coatings and that 60 percent of the surface-coating resins are tar-acid and 40 percent alkyds. The Tariff Commission found that in 1937 50 percent of the United States production of all synthetic resins went into surface coatings, 27 percent into molded articles, and the remaining 23 percent into laminating and miscellaneous uses. Approximately three-fourths of the surface-coating resins were alkyds and one-fourth tar-acid resins.

GERMANY

Production.

In recent years Germany’s production of synthetic resins has increased rapidly, each succeeding year registering the attainment of a new record. In 1933 production totaled 17,500,000 pounds and by 1935 had increased to 55,000,000 pounds. A further expansion of about 30 percent to 70,000,000 pounds in 1936 and present production trends indicate a gain of about 40 percent more in 1937, to an estimated total of 100,000,000 pounds.

Although tar-acid resins comprise the bulk of the German output, considerable gains are shown for other types, notably injection molding resins of the polystyrene and vinyl types. The development of completely automatic injection molding machinery has given an impetus to these types. While technical progress, including improvement of molding equipment, has contributed to the expanded production, the use of synthetic resins in Germany has had a strong stimulus because they are made almost wholly of domestic materials. Under the “Four-Year Plan” for the greatest possible national economic independence, synthetic resins are replacing imported materials, such as the heavier nonferrous metals, iron, hardwoods, cork, and natural gums and resins in many uses. This displacement of materials has also affected such domestic products as glass and porcelain, which caused the Government to intervene and impose restrictions upon the use of resins for purposes adequately served by other materials of German origin.

Germany’s expanding production of synthetic resin has also been aided by a sharp increase in exports, which have increased well over 100 percent since 1932.

_Tar-acid resins._—German output of tar-acid resins has been estimated at 35 million pounds in 1934, at 49 million pounds in 1935, and at 63 million pounds in 1936. Such resins comprise the bulk of the German production of molding resins.

There are at least seven producers of tar-acid resins in Germany and nine producers of molding powders and pellets. Tar-acid resins for surface coatings are produced by a number of these concerns. Among the important makers in Germany are The Bakelite Gesellschaft (organized in 1910 to operate under the Baekeland patents); the explosives and munitions firm of Dynamit A.G.; Dr. Kurt Albert G.m.b.H.; the I.G. Farbenindustrie; Beckacite Kunstharzfabrik G.m.b.H.; and Rohm & Haas A.G. The Beckacite firm has associates in the United States and in the United Kingdom, and Rohm & Haas, an associate in the United States.

_Alkyd resins._—The manufacture of alkyd resins has developed in Germany in the past few years. Demand for these resins has been given a marked impetus by the development of a new standardized substitute for linseed-oil varnish known as El Varnish, the use of which is required by the Control Board for Industrial Fats for certain interior and exterior painting.

There are five makers of resins for paints, varnishes, and lacquers. The output of alkyd resins has increased sharply since 1934, probably reaching 10 million pounds in 1936.

_Urea resins._—The output of urea resins in Germany is relatively small; two of the more important types are known as Locron and Pollopas.

_Polystyrene and vinyl resins._—In 1936 Germany’s production of thermoplastic resins exceeded 1 million pounds, principally of the polystyrene and vinyl types. Among the vinyl resins are Acronal and Mowilith, both of which are manufactured by the I.G. Farbenindustrie. This combine also produces several types of polystyrene resins known as Mollit and Metastyrol. Dynamit A.G. produces a polystyrene resin known as Trolitul.

Uses of synthetic resins.

The original and most important use of synthetic resins in Germany was for electrical insulation. This use was so extensive that the industry was organized in 1924 into an association known as non-rubber insulation materials industry. Materials were standardized and classified into 14 types, of which 5 were tar-acid resins and 1 was a urea resin. Every type must meet certain specifications in order to be recognized by the Reich Testing Institute. More than 100 firms produce insulating materials meeting the institute’s specifications.

Radio panels of the popular sets sponsored by the Government are made of synthetic resins. Consumption in the automobile industry is increasing for such parts as instrument panels, electrical equipment, steering wheels, gear-shift knobs, and numerous others. The latest airplanes show increased use of synthetic resins, where they contribute light weight, great strength, and resistance to corrosion.

In cameras and moving-picture equipment, wood and metal have been in part replaced by synthetic resins. Other applications of resins in Germany include bearings for rolling mills, goggles and spectacles (including the lens), and perfume and medicine bottles.

Resins for surface coatings are undergoing rapid development in Germany, owing to the shortage of linseed oil. Alkyd resins in coatings are being promoted by the Government, which prohibits or limits the use of the older oil-type coatings for certain uses so as to decrease the use of linseed oil and other paint oils that must be imported and hence require outlays of foreign exchange. Penalties have been imposed for violating the regulations.[13]

Organization.

The synthetic-resin industry in Germany is a unit within the national industrial organization. It is a subdivision of the industrial chemical group, called Fachgruppe Kunststoffe, or Group 13 of the 19 trade groups in the chemical division. This subdivision controls casein and cellulose plastics as well as synthetic resins, and is further divided as follows: (1) Casein plastics, (2) cast phenolic resins, (3) molding compositions, (4) resins for lacquers, (5) celluloid and zellon, (6) transparent sheeting, (7) linoleum, and (8) miscellaneous (such as vulcanized fiber, bottle caps, and die-casting resins).

There are two cartels distinct from the national organization, which expressly excludes all functions and activities of cartels. One cartel represents the firms interested in molding compositions and the other those interested in synthetic resins for other purposes. Some of the producers are members of both cartels.

Foreign trade.

Imports of synthetic resins are negligible, although the duty of 4.6 cents per pound (25 marks per 100 kilograms) on imports into Germany is not prohibitive. Exports have increased practically every year since 1930, when they were first recorded separately.

Table 23 shows the quantity and value of exports in recent years.

TABLE 23.—_Synthetic resins: German exports, 1930-37_

-------+----------------------+----------------------
| Hardening resins | Nonhardening resins
+------+---------------+------+---------------
Year | | Value | | Value
|1,000 +-------+-------+1,000 +-----+---------
|pounds|1,000 | 1,000 |pounds|1,000|1,000
| |marks |dollars| |marks|dollars
-------+------+-------+-------+------+-----+---------
| | | | | |
1930 | 2,549| 1,973| 472| | |
1931 | 3,775| 2,757| 651| | |
1932 | 3,162| 2,112| 501| | |
1933 | 4,009| 2,625| 801| 6,628|3,566| 1,088
1934 | 4,924| 3,162| 1,246| 7,076|3,415| 1,346
1935 | 4,948| 2,993| 1,206| 6,921|3,445| 1,388
1936 | 6,392| 3,501| 1,411| 7,764|3,820| 1,539
1937[1]| 8,706| 4,402| 1,770|10,866|5,389| 2,117
-------+------+-------+-------+------+-----+----------

[1] Preliminary.

Source: Consular reports.

German exports of synthetic resins are, for the most part, destined to European countries, most of which have increased their purchases considerably in recent years. Exports to Latin American countries have increased recently, especially to Brazil. Table 24 shows the distribution of exports in recent years.

TABLE 24.—_Synthetic resins: German exports, by countries, 1934-37_

[Thousands of marks]
------------------------------+-----+-----+-----+-------
Destination |1934 |1935 |1936 |1937[1]
------------------------------+-----+-----+-----+-------
Austria | 259| 352| 446| 593
Belgium | 215| 259| 297| 420
Czechoslovakia | 347| 345| 604| 825
Denmark | 316| 391| 473| 540
France | 626| 651| 680| 734
Great Britain |1,247| 563| 596| 844
Hungary | 240| 135| 182|([2])
Italy | 252| 359| 523| 615
Netherlands | 530| 572| 645|1,031
Spain | 225| 302| 178| 57
Sweden | 415| 457| 463| 691
Switzerland | 721| 705| 714| 749
Other European countries | 370| 618| 706|([2])
Argentina | 250| 207| 194|([2])
Brazil | 46| 77| 109|([2])
Other Latin American countries| 17| 18| 75|([2])
All other countries | 501| 427| 436|2,692
+-----+-----+-----+-----
Total |6,577|6,438|7,321|9,791
------------------------------+-----+-----+-----+-----

[1] Preliminary.

[2] Included in all other countries.

Source: Official German statistics.

GREAT BRITAIN[14]

As in most other countries, the history of the synthetic-resin industry in Great Britain begins with the acquisition of rights by a British concern to manufacture under the original Bakelite patents. The Damard Lacquer Co., Ltd. was probably the pioneer maker of phenolic resins in England. The principal product was a baking lacquer sold under the trade name Damarda, marketed for and used principally as a coating to prevent corrosion on brass. The outbreak of the World War created such an urgent demand for laminated materials that this firm started production of them for the British Government. In 1926 this concern was merged with Mouldesite, Ltd. and Redmanol, Ltd., under the name of Bakelite, Ltd.

Production.

Statistics of production of synthetic resins in Great Britain are available only for 1934 and 1935. They are given in table 25.

TABLE 25.—_Synthetic resins: Production in Great Britain, 1934 and 1935_

-------------------------------------------+---------------------
Type | 1934 | 1935
-------------------------------------------+----------+----------
| _Pounds_ | _Pounds_
Solid, liquid, cured, uncured, and hardened|25,558,400|13,283,200
Molding powder, 50 percent or more resin | |25,872,000
Laminated sheets, rods, blocks, tubes | 1,164,800| 1,646,400
+----------+----------
Total |26,723,200|40,801,600
-------------------------------------------+----------+----------

Source: Great Britain. Board of Trade, Census of Production.

Capital invested in the British industry is reported as 15,000,000 pounds sterling and direct employment as 20,000 people.

_Tar-acid resins._—Many large moldings are made in England, such as large radio cases, desk files, trays, and drain boards. Cast phenolic resin production has just been started in England.

Among the novelties recently produced in England is a toy railway molded of tar-acid resin. The trains and track spacers are of nonconducting resin; the molded rails are made conductive by a thin covering of metal which is pressed in and secured at the ends. Two trains may be run on the same set of rails at different speeds, or one can go forward and another backward, since the two outer rails are separate conductors, the third rail acting as a common return.

Molded piano parts are being tried in an attempt to solve the troubles hitherto encountered with wood, owing to variations in humidity. Resins have long been used in facing the keys, but the production of piano action parts has presented many technical difficulties. The secret of success with molded resin parts lies in molding the joints in position when the main body is molded. There are 88 sections in each piano.

_Urea resins._—British Cyanides, Ltd., well-known makers of synthetic resins in England, acquired the Pollopas patents for the manufacture of urea resins in the United Kingdom, in certain continental European countries, and in the British Empire except Canada. The agreement called for a full exchange of patents and other information with the other licensees of the Pollopas patents. These arrangements were made for the purpose of consolidating the patent position and for the pooling of technical data already existing on manufacture, with the object of improving quality.

_Acrylate resins._—An outstanding development in Great Britain has been the production of the thermoplastic resins known as Diakon and Perspex. These are made from methyl methacrylate and are developments of the Imperial Chemical Industries, Ltd. Diakon is for molding powders and Perspex is in the form of cast sheets, rods, tubes, and optical forms.

These new commercial resins are considered the best combination thus far obtained of strength, transparency, and light weight. Applications in England include fittings for aircraft, transparent inspection covers for machinery, medical equipment, instrument windows, lenses and prisms in optical systems, and aircraft windscreens. They are used in subways for lenses for deflecting and diffusing light and in battery cases and coil forms.

The general properties of the acrylate resins include transparency to both visible and ultraviolet light, almost unlimited color range, resistance to acids and alkalies, and superior electrical properties.

_Aniline resin._—Panilax is an aniline-formaldehyde condensation product made in England. It has high electrical and thermal insulating properties, great mechanical strength, is odorless and odor repelling, and practically unaffected by water, oil, and alkalies.

Organization.

Most of the British producers of synthetic resins are members of the British Plastics Federation, Ltd.

Several years ago a 10-year contract was made between the Imperial Chemical Industries, Ltd. and the Toledo Synthetic Products Co. (now Plaskon Co.) of Toledo, Ohio. This agreement provides for an exchange of all technical and commercial information on urea-resin products and processes and the granting of free licenses under present or future patents.

Agreements probably also exist between the British Bakelite Co. and the American firm on tar-acid resins; between Nobel Chemical Finishes, Ltd. and E. I. du Pont de Nemours & Co. on alkyd resins; between British Thompson Houston Co., Ltd., and the General Electric Co. on alkyd resins; between Imperial Chemical Industries, Ltd. and du Pont on acrylate resins; and between Beetle Products Co. and American Cyanamid Co. on urea resins.

Foreign trade in resins.

British imports of synthetic resins, by principal sources, are shown in table 26.

TABLE 26.—_Synthetic resins: Imports into the United Kingdom, in selected years, 1930-36_

[1,000 pounds]
--------------------+------+-------+-------+-------+-------+------
Source | 1930 | 1931 | 1933 | 1934 | 1935 | 1936
--------------------+------+-------+-------+-------+-------+------
British countries. | 1 | ([1]) | 5 | 2 | 19 | 24
Germany | 508 | 1,621 | 2,267 | 2,259 | 1,476 | 914
Netherlands | 679 | 667 | 151 | 114 | ([2]) | ([2])
UNITED STATES | 119 | 229 | 656 | 902 | 986 | 1,056
All other countries | 65 | 281 | 246 | 257 | 323 | 435
+------+-------+-------+-------+-------+------
Total |1,372 | 2,798 | 3,470 | 3,534 | 2,804 | 2,429
--------------------+------+-------+-------+-------+-------+------

[1] Less than 500.

[2] Included in “All other countries.”

Source: Official statistics of the United Kingdom.

British exports of synthetic resins to principal countries are shown in table 27.

TABLE 27.—_Synthetic resins: Exports from the United Kingdom, in selected years, 1930-36_

[1,000 pounds]
--------------------+------+-------+-------+-------+-------+------
Source | 1930 | 1931 | 1933 | 1934 | 1935 | 1936
--------------------+------+-------+-------+-------+-------+------
British countries | 138 | 170 | 992 | 1,350 | 1,788 | 2,732
Sweden | 40 | 69 | 242 | 452 | 558 | 650
Denmark |([1]) | ([1]) | 99 | 140 | 159 | 150
Belgium |([1]) | ([1]) | 104 | 205 | 237 | 203
Italy |([1]) | ([1]) | 49 | 95 | ([1]) | ([1])
Argentina |([1]) | ([1]) | 28 | 198 | 156 | 238
All other countries | 104 | 171 | 366 | 505 | 735 | 1,084
+------+-------+-------+-------+-------+------
Total | 282 | 410 | 1,880 | 2,945 | 3,633 | 5,057
--------------------+------+-------+-------+-------+-------+------

[1] Not available; included in “All other countries.”

Source: Official statistics of the United Kingdom.

FRANCE[15]

Producers.

Statistics of French production and sales of synthetic resin are not available. Larousse Commercial Illustré describes the French synthetic resin industry as not important and estimates the output in 1930 at 2,000,000 pounds. The Revue Général des Matières Plastiques, most important technical review in France, estimates the production in 1931 as about 3,500,000 pounds.

The comparatively few French companies producing synthetic resins are, for the most part, under British or German control. The types of synthetic resin made in France, the trade names, and the names of the manufacturers, follow:

_Bakelite._—Tar-acid molding compounds and laminating materials; cast phenolic resins; Cie La Bakelite, Bezous, Seine.

_Plastose and Ferodo._—Tar-acid molding compounds; Société Ferodo-Plastose, Saint Ouen, Seine.

_Pollopas._—Urea molding compounds and laminating materials; Établissements Kuhlmann, Paris.

Foreign trade.

French imports of synthetic resins are classified under tariff item No. 0376 bis: Synthetic resins (solid or resinous products of the Bakelite, Albertol, Plastose types, etc.) derived from the condensation of aldehydes with phenols, amines, and amides. Several subclassifications are shown: (_a_) Soluble in oil and not polymerizable, (_b_) which may be rendered insoluble and infusible, and (_c_) infusible. Imports in recent years, from principal sources, are shown in table 28.

TABLE 28.—_Synthetic resins: French imports, by types and by countries, 1931 and 1933-37_

[Pounds]
--------------+-------+---------+---------+---------+---------+----------
Source | 1931 | 1933 | 1934 | 1935 | 1936 | 1937[1]
--------------+-------+---------+---------+---------+---------+----------
|
| Soluble in oil
+-------+---------+---------+---------+---------+----------
Germany |563,860|1,003,860|1,359,600|1,164,470|1,085,766| ([2])
UNITED STATES |174,900| 126,280| 185,680| 284,458| 162,699| ([2])
United Kingdom|184,800| 131,120| 80,520| 109,789| 18,960| ([2])
Austria | | 35,640| 162,580| 193,564| 575,180| ([2])
Netherlands | | 49,720| | 16,755| ([2]) | ([2])
All other | | | | | |
countries | 4,620| 5,720| 3,080| 11,023| 33,069| ([2])
+-------+---------+---------+---------+---------+----------
Total |928,180|1,352,340|1,791,460|1,744,059|1,875,894|1,794,985
+-------+---------+---------+---------+---------+----------
| Molding compounds
+-------+---------+---------+---------+---------+----------
United Kingdom| 21,780| 71,060| 10,340| 11,243| 23,589| ([2])
Germany |248,600| 49,060| 20,460| 68,563| 39,242| ([2])
Switzerland | | 13,200| 31,900| 11,464| ([2]) | ([2])
UNITED STATES | 11,220| 18,920| 22,660| 20,062| 66,799| ([2])
Belgium | | 31,240| 49,500| 7,716| ([2]) | ([2])
All other | | | | | |
countries | 3,080| | 4,840| 6,173| 5,732| ([2])
+-------+---------+---------+---------+---------+----------
Total |284,680| 183,480| 139,700| 125,221| 135,362| 105,380
+-------+---------+---------+---------+---------+----------
| Molded, cast, and laminated articles
+-------+---------+---------+---------+---------+----------
Germany | 12,980| 7,700| 4,840| 9,039| 17,857| ([2])
Netherlands | | | | 220| | ([2])
Austria | 4,840| 440| 220| | | ([2])
United Kingdom| | | 220| | | ([2])
UNITED STATES | | 220| | 220| | ([2])
All other | | | | | |
countries | 1,320| | | | 1,984| ([2])
+-------+---------+---------+---------+---------+----------
Total | 19,140| 8,360| 5,280| 9,479| 19,841| 8,377
--------------+-------+---------+---------+---------+---------+----------
[1] Preliminary.

[2] Not separately reported.

Source: Consular reports.

Exports of synthetic resins from France, by principal markets, are shown in table 29.

TABLE 29.—_Synthetic resins: French exports 1931 and 1933-37_

[Pounds]
--------------+-------+---------+---------+---------+---------+---------
Destination | 1931 | 1933 | 1934 | 1935 | 1936 | 1937
--------------+-------+---------+---------+---------+---------+---------
Belgium |203,060| 224,180 | 186,780 | 113,757 | 165,565 | ([1])
Argentina | | 69,080 | 91,300 | ([1]) | ([1]) | ([1])
Switzerland | | | 16,940 | 12,787 | 37,258 | ([1])
Italy | 12,980| | | ([1]) | ([1]) | ([1])
All other | | | | | |
countries | 4,840| 29,260 | 15,180 | 54,895 | 36,376 | ([1])
+-------+---------+---------+---------+---------+---------
Total |220,880| 322,520 | 310,200 | 181,439 | 239,199 | 417,772
--------------+-------+---------+---------+---------+---------+---------

[1] Not separately reported.

Source: Consular reports.

CZECHOSLOVAKIA

Production of phenolic resins in Czechoslovakia has increased rapidly in recent years and is ample to supply domestic requirements. Most of the raw materials are imported from Germany, Great Britain, and France, but formaldehyde is produced locally in sufficient quantities.

The principal makers of synthetic resins in Czechoslovakia are:

(1) Bratislavska tovarna na kable Bratislava.
(2) Schreiber & Co. Lipnik
(3) Ing. Alex Reiber Sered
(4) J. Elias Prague
(5) Mathias Oechsler & Sohn Riegersdorf
(6) J. Batistello, Jr. Gablonz

Resin products are widely used by the electrical industries for wall plates, plugs, switches, fuse boxes, etc. Other articles made of synthetic resins are: handles and knobs for furniture and kitchen equipment, bottle caps, fountain pens and pencils, clock and radio housings, tableware, cutlery handles, trays, buttons, toilet ware and toys.

Imports of synthetic resins in 1934 totaled 1,270,500 pounds; Germany supplied 46 percent and Great Britain 22 percent of this total. Exports of synthetic resins during the same year amounted to 166,540 pounds and went principally to Poland, Yugoslavia, Germany, and Argentina.

ITALY

The Societa Italiana Resine, an affiliate of the important chemical firm, Chimiche Forestali, is a leading maker of tar-acid resins in Italy. A new and modern plant is located at Milan in close proximity to the electrical and textile industries, both important markets for resins.

In 1936 the Ministry of Corporations granted Montecatini Societe Generale per l’Industria Mineraria, Milan, a permit to develop a factory for alkyd resins; and also Societe Italiana Ebonite and Sostituti, Milan, one to produce tar-acid resins. In 1937 a permit was granted to Montecatini S.A. for a plant to manufacture acrylic acid resins at the Villadossola works of the Soc. Elletrochimica del Toce.

JAPAN[16]

The history of the synthetic resin industry in Japan goes back to 1913 when Dr. Jokichi Takamine, discoverer of adrenalin and takadiastase, acquired the right to manufacture and sell tar-acid resin Products in Japan. The business was financed by the Sankyo Co., Ltd., and a factory was built at Shinagawa, near Tokyo. In 1923 a subsidiary company known as the Japan Bakelite Co., Ltd., was formed with a paid-in capital of 1,200,000 yen. This firm considers itself an affiliate of the Bakelite Corporation of the United States and, according to an existing agreement, cannot export to the United States. Its territory includes the Japanese Empire and Manchukuo. China is considered an open market.

The original plant at Shinagawa was partially destroyed by fire in 1919, and the following year was moved to Mukojima, Tokyo. The firm makes tar-acid resins, and a full line of products covered by the patents of the American concern. Included are laminated sheets, molding compounds, molded articles, surface coating resins, laminated resin gears and spindles for rayon mills. An interesting development is the adaption of tar-acid resin lacquers to the production of Japanese lacquer ware such as bowls, vases, etc.

Since the establishment of the Japan Bakelite Co., several other firms have started the production of synthetic resins. The Tokyo Electric Co., an affiliate of the General Electric Co., makes tar-acid resins under the trade name Tecolite. Products are used principally for insulation, although molding compositions and molded articles such as are used by the electrical trade are commercially produced.

The Matsushita Electrical Works at Osaka are producers of tar-acid resins and articles made therefrom. The output is used largely for radio and electrical equipment. The Nissholite Manufacturing Co., Ltd., with a factory at Yasui-cho, Uzumasa, Kyoto specializes in decorative laminated material sold under the trade name Nissholite. The Japan Nitrogenous Fertilizer Co. (Nippon Chisso Hirijo Kabushiki Kaisha) is an important maker of tar-acid resins, marketing them under the trade names Chissolite, Safeloid, and Minaloid. The Yokahama Resin Co., a relatively small company, produces tar-acid resins and markets them in the form of molding powders. The firms listed account for practically all of the Japanese production of synthetic resins and for about 50 percent of the molded articles made from them. The remaining 50 percent of the output of molded articles is made by a large number of small firms, the majority being household industries. It is reported that there are about 2,000 of these so-called plants already engaged in this relatively new industry.

Production.

The Japanese production of manufactures of tar-acid resin reported by the Department of Commerce and Industry is shown in table 30. These data include the output of plants employing more than five operators and apparently account for only half of the total.

TABLE 30.—_Manufactures of tar-acid resins: Production in Japan, 1929-35_

------------+-----------+----------------------------------------
| | Value
| +-------------+---------------+----------
Year | Quantity | | |
| | Of quantity | Additional[1] | Total
| | reported | |
------------+-----------+-------------+---------------+----------
| _Pounds_ | | |
1929 | 28,681 | $46,594 | $125,404 | $171,998
1930 | 607,800 | 52,409 | 442,583 | 494,992
1931 | 744,119 | 99,907 | 268,594 | 368,501
1932 | 286,422 | 36,584 | 367,220 | 403,804
1933 | 229,854 | 26,747 | 516,903 | 543,650
1934 | 1,435,977 | 193,857 | 926,951 | 1,120,808
1935 | 3,176,441 | 477,526 | 923,546 | 1,401,072
------------+-----------+-------------+---------------+----------

[1] Quantity not reported.

Source: Factory statistics of Department of Commerce and
Industry, Japan.

Estimates from other sources of Japanese productions of tar-acid resins indicate an output of 2,600,000 pounds of resin and 3,600,000 pounds of molded resin articles in 1933, and of 4,900,000 pounds of resin and 7,500,000 pounds of resin articles in 1935.

It was recently announced that the Gosei Chemical Co. will manufacture vinyl resins in Japan. This firm’s principal interest is in acetate fiber and rayon manufacture. Later in 1936 the Showa Fertilizer Co. announced the successful development of a process for making urea. Urea resins are in commercial production by the Toyo Gosei Kagaku Kogyo K.K., an affiliate of Chugoku Toyo K.K.

The resin industry in Japan is expected to undergo considerable development in the near future. Raw materials are available in sufficient quantities and the art of molding is fairly well developed.

CANADA

The producers of synthetic resins in Canada are:

Bakelite Corporation of Canada, Ltd. Toronto.
Shawinigan Chemicals, Ltd. Shawinigan Falls.
Canadian General Electric Co. Toronto.
Canadian Industries, Ltd. Toronto.

The Bakelite Corporation of Canada, Ltd., an affiliate of the firm of the same name in the United States, was formed in 1925. This plant makes molding materials, laminating materials, and an extensive line of technical varnishes. Molded parts were made at this factory until 1932.

Shawinigan Chemicals, Ltd. is the pioneer organic chemical maker in Canada. A modern plant at Shawinigan Falls, Quebec, produces synthetic acetic acid, acetaldehyde, vinyl acetate, vinyl resins, and other chemicals. The vinyl resins manufactured by this firm have already been described (see p. 44). Appreciable quantities of these resins have been exported to the United States in the past but the construction of a factory (jointly owned by Shawinigan Chemicals, Ltd., and the Fiberloid Corporation) at Indian Orchard, Mass., for the manufacture of vinyl resins will probably result in a decrease of exports from Canada to the United States.

The Canadian General Electric Co. makes alkyd resins for use in surface coatings. Phthalic anhydride and other raw materials are imported from the United States. Canadian Industries, Ltd., produces alkyd resins at a plant in Toronto, Ontario.

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Synthetic resins and their raw materialsChapter V: Part 5

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