Editing Bakelite (section)

==Synthesis==
{{external media | width = 210px | float = right | headerimage= | video1 = "[https://www.youtube.com/watch?v=phNLecfyWS8 Making Bakelite Plastic]", [[NileRed]]}}

Making Bakelite is a multi-stage process. It begins with the heating of phenol and formaldehyde in the presence of a catalyst such as hydrochloric acid, [[zinc chloride]], or the base ammonia. This creates a liquid condensation product, referred to as ''Bakelite A'', which is soluble in alcohol, acetone, or additional phenol. Heated further, the product becomes partially soluble and can still be softened by heat. Sustained heating results in an "insoluble hard gum". However, the high temperatures required to create this tend to cause violent foaming of the mixture when done at standard atmospheric pressure, which results 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 about {{convert|150|C|F}}, Baekeland was able to suppress the foaming that would otherwise occur. The resulting substance is extremely hard and both infusible and insoluble.<ref name=CookSlessor/>{{rp|67}}<ref name="Meikle"/>{{rp|38–39}}

<gallery widths="200px" class="center">
File:Weigh Room Liquid Materials 1935 Bakelite Review Silver Anniversary p12.tif | Weigh room
File:Still room 1935 Bakelite Review Silver Anniversary p12.tif | Still room
File:Bakelite Cooling Room 1935 Bakelite Review Silver Anniversary p13.tif | Cooling room
File:Resin and Varnish inspection laboratory 1935 Bakelite Review Silver Anniversary p17.tif | Resin and varnish inspection laboratory
File:Test samples 1935 Bakelite Review Silver Anniversary p17.tif | Testing resin samples
File:Resin and Varnish Development Laboratory 1935 Bakelite Review Silver Anniversary p17.tif | Development laboratory
</gallery>

===Compression molding===
[[File:RotorBakelite-2.jpg|thumb|upright|A combustion engine's spark [[distributor]] rotor made of Bakelite]]

Molded Bakelite forms in a condensation reaction of phenol and formaldehyde, with wood flour or asbestos fiber as a filler, under high pressure and heat in a time frame of a few minutes of [[Curing (chemistry)|curing]]. The result is a hard plastic material.<ref>{{cite web|url=http://www.rsc.org/chemistryworld/podcast/CIIEcompounds/transcripts/bakelite.asp|title=Chemistry in its element – bakelite|website=Royal Society of Chemistry – RSC.org|last=Clegg|first=Brian|access-date=May 4, 2014|archive-url=https://web.archive.org/web/20140504173337/http://www.rsc.org/chemistryworld/podcast/CIIEcompounds/transcripts/bakelite.asp|archive-date=May 4, 2014|url-status=dead}}</ref> Asbestos was gradually abandoned as filler because many countries banned the production of asbestos.<ref name="fundermax.at"/>{{rp|9}}<ref name=":0">{{Cite web |title=Molded Asbestos Plastic Products - Brands & Products |url=https://www.asbestos.com/products/plastics/ |access-date=2024-11-19 |website=Mesothelioma Center - Vital Services for Cancer Patients & Families |language=en}}</ref>

Bakelite's molding process had a number of advantages. Bakelite resin could be provided either as powder or as preformed partially cured slugs, increasing the speed of the casting. Thermosetting resins such as Bakelite required heat and pressure during the molding cycle but could be removed from the molding process without being cooled, again making the molding process faster. Also, because of the smooth polished surface that resulted, Bakelite objects required less finishing.<ref name=Metallography>{{cite book|last1=Vander Voort|first1=George F.|title=Metallography, Principles and Practice|date=1984|publisher=McGraw-Hill|location=New York|isbn=978-1615032365|pages=75–81|edition=1|url=https://books.google.com/books?id=GRQC8zYqtBIC&pg=PA75}}</ref> Millions of parts could be duplicated quickly and relatively cheaply.<ref name="Meikle"/>{{rp|42–43}}

===Phenolic sheet===
Another market for Bakelite resin was the creation of phenolic sheet materials. A phenolic sheet is a hard, dense material made by applying heat and pressure to layers of paper or glass cloth impregnated with synthetic resin.<ref name="Meikle"/>{{rp|53}} Paper, cotton fabrics, synthetic fabrics, glass fabrics, and unwoven fabrics are all possible materials used in lamination. When heat and pressure are applied, [[polymerization]] transforms the layers into [[Thermosetting plastic|thermosetting]] industrial laminated plastic.<ref name=Nimrod>{{cite web|title=Bakelite|url=http://www.nimrodplastics.com.au/product-bakelite.htm|website=Nimrod Plastics|access-date=February 26, 2015|archive-date=April 19, 2020|archive-url=https://web.archive.org/web/20200419111644/http://www.nimrodplastics.com.au/product-bakelite.htm|url-status=dead}}</ref>

Bakelite phenolic sheet is produced in many commercial grades and with various additives to meet diverse mechanical, electrical, and thermal requirements. Some common types include:<ref name=Micarta>{{cite web|title=Micarta ® Laminates – Various Grades Technical Information|url=http://www.professionalplastics.com/professionalplastics/MicartaGrades-DataSheet.pdf |archive-url=https://ghostarchive.org/archive/20221009/http://www.professionalplastics.com/professionalplastics/MicartaGrades-DataSheet.pdf |archive-date=2022-10-09 |url-status=live|website=Professional Plastics|access-date=February 26, 2015}}</ref>
* Paper reinforced [[National Electrical Manufacturers Association|NEMA]] XX per MIL-I-24768 PBG. Normal electrical applications, moderate mechanical strength, continuous [[operating temperature]] of {{convert|250|°F}}.
* Canvas-reinforced NEMA C per MIL-I-24768 TYPE FBM NEMA CE per MIL-I-24768 TYPE FBG. Good mechanical and impact strength with a continuous operating temperature of 250 °F.
* Linen-reinforced NEMA L per MIL-I-24768 TYPE FBI NEMA LE per MIL-I-24768 TYPE FEI. Good mechanical and electrical strength. Recommended for intricate high-strength parts. Continuous operating temperature convert 250 °F.
* Nylon reinforced NEMA N-1 per MIL-I-24768 TYPE NPG. Superior electrical properties under humid conditions, fungus resistant, continuous operating temperature of {{convert|160|°F}}.