During the 1930s and 1940s, the DuPont company commercialized organofluorine compounds at large scales. Following trials of chlorofluorocarbons as refrigerants by researchers at General Motors, DuPont developed large-scale production of Freon-12. The work was carried out by DuPont scientist Dr. Thomas Midgley Jr. DuPont and GM formed a joint venture in 1930 to market the new product; in 1949 DuPont took over the business. Freon proved to be a marketplace hit, rapidly replacing earlier, more toxic, refrigerants and growing the overall market for kitchen refrigerators.
In 1938, polytetrafluoroethylene (Teflon) was discovered by accident by a recently hired DuPont PhD, Roy J. Plunkett. While working with a cylinder of tetrafluoroethylene, he was unable to release the gas, although the weight had not changed. Scraping down the container, he found white flakes of a polymer new to the world. Tests showed the substance was resistant to corrosion from most substances and had better high temperature stability than any other plastic. By early 1941, a crash program was making commercial quantities.
Large-scale productions of elemental fluorine began during World War II. Germany used high-temperature electrolysis to produce tons of chlorine trifluoride, a compound planned to be used as an incendiary. The Manhattan project in the United States produced even more fluorine for use in uranium separation. Gaseous uranium hexafluoride was used to separate uranium-235, an important nuclear explosive, from the heavier uranium-238 in diffusion plants. Because uranium hexafluoride releases small quantities of corrosive fluorine, the separation plants were built with special materials. All pipes were coated with nickel; joints and flexible parts were fabricated from Teflon.
In 1958, a DuPont research manager in the Teflon business, Bill Gore, left the company because of its unwillingness to develop Teflon as wire-coating insulation. Gore's son Robert found a method for solving the wire-coating problem and the company W. L. Gore and Associates was born. In 1969, Robert Gore developed an expanded polytetrafluoroethylene (ePTFE) membrane which led to the large Gore-Tex business in breathable rainwear. The company developed many other uses of PTFE.
In the 1970s and 1980s, concerns developed over the role chlorofluorocarbons play in damaging the ozone layer. By 1996, almost all nations had banned chlorofluorocarbon refrigerants and commercial production ceased. Fluorine continued to play a role in refrigeration though: hydrochlorofluorocarbons (HCFCs) and hydrofluorocarbons (HFCs) were developed as replacement refrigerants.