In 1952, the research manager of an aerosol filling company asked this writer if there were any liquefiable
propellants less costly than chlorofluorocarbons (CFCs). Hydrocarbons, such as butanes, were mentioned,
but soundly rejected due to their flammability and bad odors. How things have changed…
Much later, a historical review disclosed how flammable propellants played a role in the foundation of our
industry. The first self-pressurized dispenser is attributed to J. Savare (1837), who used CO2 to produced spritzers
as an adjunct to beverage consumption. Next came J.D. Lydel (1862) with fragrance sprays, complemented by
Helbing & Perzlich (1889) who used dimethyl ether. C.L. Gebauer (1901) patented flammable
ethyl chloride in 4oz. glass tubes to dispense skin chilling sprays for topical surgeries.
Still later, Eric Rotheim of Oslo, Norway published U.S. Patents 1,800,156 (1931) and
1,892,750 (1933) describing heavy-duty containers of insecticides, ski-waxes and other products,
pressurized with vinyl chloride monomer (VCM), dimethylether (DME), butane and
CO2. The first three propellants were quite flammable. Since Rotheim did his laboratory
work in his home basement, fairly close to a coal-fired house furnace, he must have been
very careful to avoid possible gas-air explosions. He marketed at least 6,000 of his pressurized
dispensers, asking customers to return the costly cans for refilling. Most did not.
He and his partner dissolved their small business and Rotheim died a short while later,
unaware of his future international appreciation as the “Father of the Aerosol Industry.”
His work was continued by C.R. Iddings, U.S. Patent 2,070,167 (1937) and several other
inventors.
The first non-flammable chlorofluorocarbon gas (CFC-12) made its debut in 1933.
DuPont had developed its Freon-12 (CCl2F2) as a coolant for automobile air-conditioners. Related compounds,
such as Freon-11 (CCl3F) and Freon-114 (mostly CClF2–CClF2) were introduced a short time later. By 1941, the
Second World War was at its height. U.S. Marines were in the South Pacific fighting the Japanese entrenched
in Guadalcanal and other islands. They had two enemies: the Japanese and hordes of biting mosquitoes. When
army commanders made Congress well aware of the insect problem, Dr. Lyle D. Goodhue (an entomologist) and
Captain William N. Sullivan, P.E. (an engineer) at the U.S. Dept. of Agriculture (USDA) “Bug Lab” in Beltsville,
MD were tasked with finding a solution. Goodhue was aware of Rotheim’s work a decade earlier. He coupled it
with the development of Freon-12 and the result was the highly successful “Bug Bomb.” As an added bonus, enterprising
Marines found that the quickly evaporating spray could chill a warm can of beer, making the beverage
much more enjoyable.
Urgent requests for more “Bug Bombs” ensued. Production skyrocketed. The
Bridgeport Brass Co. and others produced the heavy-duty canisters on a 168-hourper
week schedule. Other firms filled them with formulations such as:
• 5% of a 20% Pyrethrum Solution in Kerosene Base Oil
• 1% Sesame Oil (Synergist)
• 9% Low-odor Petroleum Distillate
• 85% Freon-12
Many millions of these “Bug Bombs” were produced and delivered to U.S. troops
during the remaining war years. Afterward, they were made available to the public,
although the high price of the heavy duty steel canisters depressed sales somewhat.
However, it inspired U.S. can companies to develop lightweight containers. In
1946, Sullivan used the word “aerosol” for the first time when addressing a convention
of entomologists in Washington, D.C. While technically incorrect, the name
soon replaced the somewhat repugnant “Bug Bomb” or “Bomb.”
In 1941, Goodhue and Sullivan applied for a public service patent, which was granted in 1943—currently giving
the U.S. Environmental Protection Agency (EPA) administrative control over insecticides, disinfectants, rodenticides
and related products.
Montfort A. Johnsen, Ph.D.
Technical Editor
Hydrocarbons vs.
Chlorofluorocarbons
as Aerosol Propellants
Dr. Lyle D. Goodhue
The original “Bug Bomb”
32 Spray December 2018