Nylon
Nylon is a family of synthetic polymers characterized by amide linkages, typically connecting aliphatic or semi-aromatic groups.
Nylons are generally brownish in color and can possess a soft texture, with some varieties exhibiting a silk-like appearance. As thermoplastics, nylons can be melt-processed into fibers, films, and diverse shapes. The properties of nylons are often modified by blending with a variety of additives.
Numerous types of nylon are available. One family, designated nylon-XY, is derived from diamines and dicarboxylic acids of carbon chain lengths X and Y, respectively. An important example is nylon-6,6. Another family, designated nylon-Z, is derived from aminocarboxylic acids with carbon chain length Z. An example is nylon-.
Nylon polymers have extensive commercial applications, including uses in textiles and fibers, molded components for automotive and electrical equipment, and films.
History
DuPont and the invention of nylon
Researchers at DuPont began developing cellulose-based fibers, culminating in the synthetic fiber rayon. DuPont's experience with rayon was an important precursor to its development and marketing of nylon.DuPont's invention of nylon spanned an eleven-year period, ranging from the initial research program in polymers in 1927 to its announcement in 1938, shortly before the opening of the 1939 New York World's Fair. The project grew from a new organizational structure at DuPont, suggested by Charles Stine in 1927, in which the chemical department would be composed of several small research teams that would focus on "pioneering research" in chemistry and would "lead to practical applications". Harvard instructor Wallace Hume Carothers was hired to direct the polymer research group. Initially he was allowed to focus on pure research, building on and testing the theories of German chemist Hermann Staudinger. He was very successful, as research he undertook greatly improved the knowledge of polymers and contributed to the science.
Nylon was the first commercially successful synthetic thermoplastic polymer. DuPont began its research project in 1927.
The first nylon, nylon 66, was synthesized on February 28, 1935, by Wallace Hume Carothers at DuPont's research facility at the DuPont Experimental Station. In response to Carothers' work, Paul Schlack at IG Farben developed nylon 6, a different molecule based on caprolactam, on January 29, 1938.
In the spring of 1930, Carothers and his team had already synthesized two new polymers. The first was neoprene, a synthetic rubber widely used during World War II. The second was an elastic paste that became very strong upon cooling; this would later become nylon. After these discoveries, Carothers' team was made to shift its research from a more pure research approach investigating general polymerization to a more practically focused goal of finding "one chemical combination that would lend itself to industrial applications".
It was not until the beginning of 1935 that a polymer called "polymer 6-6" was finally produced. Carothers' coworker, Washington University alumnus Julian W. Hill had used a cold drawing method to produce a polyester in 1930. This cold drawing method was later used by Carothers in 1935 to fully develop nylon. The first example of nylon was produced on February 28, 1935, at DuPont's research facility at the DuPont Experimental Station. It had all the desired properties of elasticity and strength. However, it also required a complex manufacturing process that would become the basis of industrial production in the future. DuPont obtained a patent for the polymer in September 1938, and quickly achieved a monopoly of the fiber. Carothers died 16 months before the announcement of nylon, therefore he was never able to see his success. The name "Nylon" came from the modification of norun into a unique name that could be used to market the product but was not trademarked.
Nylon was first used commercially in a nylon-bristled toothbrush in 1938, followed more famously in women's stockings or "nylons" which were shown at the 1939 New York World's Fair and first sold commercially in 1940, whereupon they became an instant commercial success with 64 million pairs sold during their first year on the market. During World War II, almost all nylon production was diverted to the military for use in parachutes and parachute cord. Wartime uses of nylon and other plastics greatly increased the market for the new materials.
The production of nylon required interdepartmental collaboration between three departments at DuPont: the Department of Chemical Research, the Ammonia Department, and the Department of Rayon. Some of the key ingredients of nylon had to be produced using high pressure chemistry, the main area of expertise of the Ammonia Department. Nylon was considered a "godsend to the Ammonia Department", which had been in financial difficulties. The reactants of nylon soon constituted half of the Ammonia Department's sales and helped them come out of the period of the Great Depression by creating jobs and revenue at DuPont.
DuPont's nylon project demonstrated the importance of chemical engineering in industry, helped create jobs, and furthered the advancement of chemical engineering techniques. In fact, it developed a chemical plant that provided 1800 jobs and used the latest technologies of the time, which are still used as a model for chemical plants today. The ability to acquire a large number of chemists and engineers quickly was a huge contribution to the success of DuPont's nylon project. The first nylon plant was located at Seaford, Delaware, beginning commercial production on December 15, 1939. On October 26, 1995, the Seaford plant was designated a National Historic Chemical Landmark by the American Chemical Society.
Early marketing strategies
An important part of nylon's popularity stems from DuPont's marketing strategy. DuPont promoted the fiber to increase demand before the product was available to the general market. Nylon's commercial announcement occurred on October 27, 1938, at the final session of the Herald Tribunes yearly "Forum on Current Problems", on the site of the approaching New York City world's fair. The "first man-made organic textile fibre" which was derived from "coal, water and air" and promised to be "as strong as steel, as fine as the spider's web" was received enthusiastically by the audience, many of them middle-class women, and made the headlines of most newspapers. Nylon was introduced as part of "The world of tomorrow" at the 1939 New York World's Fair and was featured at DuPont's "Wonder World of Chemistry" at the Golden Gate International Exposition in San Francisco in 1939. Actual nylon stockings were not shipped to selected stores in the national market until May 15, 1940. However, a limited number were released for sale in Delaware before that. The first public sale of nylon stockings occurred on October 24, 1939, in Wilmington, Delaware. 4,000 pairs of stockings were available, all of which were sold within three hours.Another added bonus to the campaign was that it meant reducing silk imports from Japan, an argument that won over many wary customers. Nylon was even mentioned by President Roosevelt's cabinet, which addressed its "vast and interesting economic possibilities" five days after the material was formally announced.
However, the early excitement over nylon also caused problems. It fueled unreasonable expectations that nylon would be better than silk, a miracle fabric as strong as steel that would last forever and never run. Realizing the danger of claims such as "New Hosiery Held Strong as Steel" and "No More Runs", DuPont scaled back the terms of the original announcement, especially those stating that nylon would possess the strength of steel.
Also, DuPont executives marketing nylon as a revolutionary man-made material did not at first realize that some consumers experienced a sense of unease and distrust, even fear, towards synthetic fabrics. A particularly damaging news story, drawing on DuPont's 1938 patent for the new polymer, suggested that one method of producing nylon might be to use cadaverine, a chemical extracted from corpses. Although scientists asserted that cadaverine was also extracted by heating coal, the public often refused to listen. A woman confronted one of the lead scientists at DuPont and refused to accept that the rumour was not true.
DuPont changed its campaign strategy, emphasizing that nylon was made from "coal, air and water", and started focusing on the personal and aesthetic aspects of nylon, rather than its intrinsic qualities. Nylon was thus domesticated, and attention shifted to the material and consumer aspect of the fiber with slogans like "If it's nylon, it's prettier, and oh! How fast it dries!".
Production of nylon fabric
After nylon's nationwide release in 1940, its production ramped up significantly. In that year alone, 1300 tons of the fabric were produced, marking a remarkable start for this innovative material.: 100 The demand for nylon surged, particularly for nylon stockings, which became an instant sensation. During their first year on the market, an astounding 64 million pairs of nylon stockings were sold, reflecting the fabric's rapid integration into daily life and fashion.: 101 Such was the success of nylon that in 1941, just a year after its launch, a second plant was opened in Martinsville, Virginia, to meet the growing demand and ensure a steady supply of this popular fabric. This expansion underscored the profound impact nylon had on the textile industry and its rapid rise to prominence as a versatile and sought-after material.While nylon was marketed as the durable and indestructible material of the people, it was sold at about one-and-a-half times the price of silk stockings. Sales of nylon stockings were strong in part due to changes in women's fashion. As Lauren Olds explains: "by 1939 had inched back up to the knee, closing the decade just as it started off". The shorter skirts were accompanied by a demand for stockings that offered fuller coverage without the use of garters to hold them up.
However, as of February 11, 1942, nylon production was redirected from being a consumer material to one used by the military. DuPont's production of nylon stockings and other lingerie stopped, and most manufactured nylon was used to make parachutes and tents for World War II. Although nylon stockings already made before the war could be purchased, they were generally sold on the black market for as high as $20.
Once the war ended, the return of nylon was awaited with great anticipation. Although DuPont projected yearly production of 360 million pairs of stockings, there were delays in converting back to consumer rather than wartime production. In 1946, the demand for nylon stockings could not be satisfied, which led to the nylon riots. In one instance, an estimated 40,000 people lined up in Pittsburgh to buy 13,000 pairs of nylons. In the meantime, women cut up nylon tents and parachutes left from the war in order to make blouses and wedding dresses. Between the end of the war and 1952, production of stockings and lingerie used 80% of the world's nylon. DuPont put focus on catering to the civilian demand, and continually expanded its production.