The invention of Nylon
Like
many great invention, nylon was a by-product of the work started back
in 1926 in the Du Point laboratories
Dr. Wallace Hume Caruthers joined the Du Point laboratories in 1928 as
head of organic chemistry research at the Wilmington laboratory
Delaware.
Wallace Carothers was born on April 27 1896 started his career at
Capital City Commercial College in Des Moines, Lowa, in a program of
accountancy and secretarial administration, whist teaching accountancy
at the Tarkio College in Missouri he studied science, as an
undergraduate student was appointed head of chemistry, Although a
talented chemist the real reason for his appointment was the shortage
of suitable people due to World War 1.
He
received his PhD from the University of Illinois and then became a
professor at Harvard where he first started his research into chemical
structures of polymers in1924.
By 1928 the DuPont chemical company opened an Organic Chemicals
research
laboratory for the development of artificial materials, deciding that
basic research was the way to go - not a common path for a company to
follow at the time, it's reported that DuPont were investing $20,000
per month into this laboratory.
DuPont’s Charles Stine (Stine known for his work on developing TNT
established the Organic Chemicals Division within the DuPont Chemical
Department in 1916 by 1930 Charles Stine was made a vice president and
director of DuPont in 1930) he recruited Dr. Carothers for the
fundamental research program that Stine was then organizing. Elmer K.
Bolton, Carothers’s immediate boss, asked him to investigate the
chemistry of an acetylene polymer that might lead to a synthetic rubber.
April 1930, Carothers’ team discovered neoprene synthetic rubber and
synthesized the first polyester super polymer, the forerunner of nylon.
April 1930 and a lab assistant working with
esters–compounds which
yield an acid and an alcohol or phenol in reaction with
water–discovered a very
strong polymer that could be drawn into a fibre. This polyester fibre
had a low
melting point, however. Carothers changed course and began working with
amides,
which were derived from ammonia.
1935 Carothers found a strong polyamide fibre that
stood up well to
both heat and solvents. He evaluated more than 100 different polyamide
before
choosing one for development.
Dr. Carothers married Helen Sweetman in 1936, a colleague of his at
DuPont. A
year later, April 29th 1937 he tragically committed suicide alone in a
hotel in
Philadelphia after a lifelong bout with depression.
Nylon changed the way people dressed worldwide and rendered the term
"silk
stocking"–once an epithet directed at the wealthy elite–obsolete.
The very first nylon stocking
Nylon stocking were brought to market
remarkably quickly, in part due to Dupont's learning from there
experience with rayon
and missing out on that market.
After determining that low-cost
production were possible and settling on a target market (women's
hosiery), Dupont produced a preliminary batch of nylon staple to
confirm that the nylon hose would be practical, the sample was
delivered to a commercial knitting mill under conditions of extreme
secrecy (the research chemist who delivered the samples to the mill
even slept with the sample on the train).
It took two test runs and a little further
development to convince Dupont to build a pilot plant in Wilmington,
then finally a full-scale production facility in Seaford Delaware on
the 30 th of March 1939 Dupont made an agreement with ICI (Imperial
Chemical Company) for the exclusive rights to produce nylon in the UK,
in conjunction with ICI rivals Courtaulds, together they set up a
third company called British Nylon Spinners Ltd (BNS)
The very first pair of nylon stocking
when on sale as a small trial in a department store in
Wilmington, Delaware (U.S.A) made by Du Point on the 27 October 1939
just to test the market.
They were a huge success with ladies
coming from miles around to buy the new nylon stockings, the store sold
out in a few hours as news spread about the area about these stockings.
On the 3rd of September 1939 Britain and France declared war
on Germany
following the German invasion of Poland a month before Du point
launched their
nylon stockings.
January 1940 ICI transferred its exclusive rights for a fee
over to British
Nylon Spinners (BNS) to manufacture and distribution of nylon yarn in
the UK,
because British was at war the priority of the production of nylon was
given
over to war production of rope and parachutes along with other war
related
product instead of yarn for the production of stockings.
By the 15th of May 1940 the USA the first nylons stocking when
on sale to
the general public for the first time selling over 72,000 pairs in the
first
day alone.
The total sales for the first year are estimated to have been
around 64 million
pairs With these new nylon stocking du point captured 30% of hosiery
market,
although there wear plenty of nylons available for the ladies in
the
United States very few pairs would find their way across the Atlantic
Ocean and
onto the legs of the UK ladies. This was because of the
success the
Germans were having in cutting Britain off from America with
their
"U" boats fleet sinking an average of 22,000 tons of ships each month
from the merchant fleet. Only essential supplies to keep the British
war effort
going was brought across this dangerous route nylon stocking were not
one of
the essentials needed in the UK.
This fun photo which might have been staged by the
photographer shows a lady
who look so pleased to be able to buy a pair of stocking has decided to
put
them on whist sat in pubic on the side walk.
The British Nylon Spinners had their first production plant in
operation in
Coventry by 23 January 1940, it's total output of nylon gong to fill
government
contracts for war materials, a second plant Stow Market was also
confined to
government production mainly nylon for parachute fabric.
With very few pairs of nylon stocking to wear ladies had to
"make do
and mend" a term which would become all too familiar as the war
progressed
in the UK.
By
1941 clothing rationing come in to effect in the UK, The government
controlled the styles of clothes and how they were made to reduce the
quantity
of raw materials require to make them this was called the CC41
standard,
the number of individual items a person could buy was restricted by
issuing
clothing coupons.
Stockings were rationed like all clothing (except second-hand clothes)
a lady
required 2 clothing coupons to buy 1 pair of stocking out of her total
allocation of 66 coupons per year (1941) by the end of rationing the
allocation
had fallen down to 36 per year cotton, silk and wool stocking all came
under
the CC41 regulations.
The number of coupons an
person
needed
to buy a item?
The number of clothing coupons which were needed to buy
an item was
published by the board of trade in newspapers like the one on the left.
The US government followed with their rationing on the 7th
December 1941
forming the war production board (WPB), this was to regulate the
production and
allocation of materials.
Nylon now came under the control of this board the amount of
fibre used in
civilian clothing was now restricted so by that 1943 it was nearly
impossible
to buy a pair of the new nylons in a store in the USA.
Du point ceased production of nylon stockings and switched
over to making
parachutes, air-plane cords and ropes, it's Seaford plant made
parachutes and
b-29 bomber tires with mainly a female work force as many men when into
the
armed force.
It also has to be mentioned that at this time Germany had also
developed a man-made
fibre in top secret called Perlon a synthetic fibre similar to the
American
nylon - this was invented by the German chemist Dr. Paul Schlack at
I.G.-Farben. They also had a test run to make Perlon into ladies
stocking after
which it was declared to be a military defense material under the code
name
"Perluran" be one again production was diverted mainly into the German
war preparation and later the war itself.
Join the forces and you would have some stocking issued
For the ladies joining one of the armed forces then things
were lightly
different as you would be issued with a uniform which would include
3pairs of
cotton lisle stockings and two suspender belts/corset, it's probable
with time
that the female service personnel would sneak in their own hosiery and
undergarments but this was against regulations.
There are stories of the female work force at the top secrete Bletchley
park
drying their underwear next to the hot computers, which was of course
was very
much looked down upon.
USA enters the war and
there are now a few more pair's nylons
around.
With the build up a American troops
in preparation for the
invasion of Europe a small number of nylon stocking were brought into
the UK by
these GI's.
Compared to the potential demand this was still a very small number,
mainly
they would be given out to their girlfriends.
At this time they might have been a small number of nylons made during
the war
years these would be mainly for proper gander purposes it very
difficult to be
certain about this.
The
lengths that women would go to wear a pair of stockings.
These are a very rare pair of nylon stocking as you can see
they are new and
unworn made in the UK by, they have the CC41 mark in the top right of
each
stocking, close examination shows these stocking are not as sheer as
you
imagine.
Now with a shortage of stocking ladies would re-sort to
wearing the hosiery
they already had store away for special occasion pre-wartime, these m
would
have been silk stockings, cotton lisle or rayon.
Life without stockings
The majority of ladies would not have nylons to wear
from an
estimation only 1% of ladies wore nylons regularly the
others had to become very resourcefully because it
was thought that a lady without stockings was improperly dressed if she
was out in public.
Ladies started to draw a line down the
back of their leg to achieve the look of wearing stocking using an eye
brow pencil or something similar to give this seamed effect.
For drawing a seam on your e.g. Max factor brought out a
devise
which helped
to guide her to create a straight seam down the back of her leg ( left
photo)
instead of doing y or have someone ( left photo ) do it for you.
Occasionally ladies would even try to colour their legs with
gravy browning
mixed with a cream other home-made formula were developed using other
house
hold products to produce the desired effect, the problem I am told is
if it
rained when she was wearing some of these it would end up be a streaky
mess
down her leg.
A multitude of commercial products were also marketed towards
the end of the
war for colouring your legs to look like they were wearing stockings
max factor
brought out a cream around this time to simulate stockings which was
applied in
a similar way to normal face foundation today.
Path'e news made a news real showing this cream been applied
by a lady to
her legs, cosmetic were also rationed in war time so the max factor
cream might
also have been hard to come by another way to simulate a seam of a
stocking was
have a line tattooed on the back of their legs, this was more often
done by
wife of seamen, who were used to seeing tattoos on their husbands as a
long
tradition with seamen. Today a few ladies still decide to have a tattoo
seam
done.
For the ladies who did have a pair of nylons to wear the worst
thing that could
happen was when she got a ladder or run in them as nylons were so
precious products were marketed to help her minimize the damage by
sealing the thread.
One such product was called lad stick manufactured
by Griffith
& associates Ltd of Bristol, most likely made in the latter
half
of the 40's.
Instruction are printed on the back of the packet telling the lady to
moisten the tip of the stick in her mouth and rub it onto the top and
bottom of the run, it also says that the substance used is not harmful
for her, it's the same principle which was used more recently with nail
varnish.
Wartime black market nylons.
With the general shortage of nylon stocking it's
inevitable that an
illegal black market would soon sprung up it is very unclear how all
the
stocking found their way onto the black market, the cost of a
pair of
nylon stocking on the black market could be as much as $20 in the U.S.A.
There are several true stories about nylons stocking been made
especially
for the black market in the U.S.A, one is where thirteen cases of nylon
yarn
was stolen in transit to a parachute factory eventually ending up at a
hosiery
mill where the yarn was made up into stocking.
Another story was about a silk mill who had a contract to make
glider tow
rope and with a little false accounting managed to make a large
quantity of
yarn disappear, subsequently making this yarn up into nylon stocking.
Other cases included rayon stockings been sold as "nylons".
The
documentation for these along with other examples is held at the
smithsonian.org there must have been many more black market nylons
stocking
schemes which when undetected throughout the war years.
Post war years and we have
nylons again
Production of nylon yarn for stocking
started up again in
the UK in December 1946 the production of yarn was controlled as it was
destined for the export market to earn valuable money for the country,
going to
only to a few hosiery knitters who were on a what was called the "
Preferred list" Aristoc been one of them along with I. R Morley's these
companies were chosen because of its large number of contact they had
abroad to
market the nylon efficiently. Nylon stocking for home consumption was
still
restricted as the clothing rationing did not end until 1951.
British nylon spinners had the
capacity supply most
industries with their requirements for nylon yarn, at that time it had
the largest
factor floor in Europe with approx. 15 looms going all day, clothing
might be
the exception this as rationing remained in force until 1951.
In the USA the production of nylon yarn
and also stockings which were destined to be sold to the ladies started
again in 1946 it took a little while before the production was
satisfying demand and in several cities including Pittsburgh fights
broke out in the street when 40,000 ladies queued up for only 13,000
pairs of nylon, called "the nylon riots" in the popular press.
By the mid 1950's nylons were readily available again for any lady the
buy whenever they wanted a pair, these stockings were very much sheerer
than what was seen in previous decades with a much larger range of
shades.
The hosiery manufacture by now had time to buy brand new knitting
machines and install them into their mill like the one above these were
American Reading machines.