MODIFIED PHENOLIC RESOL RESIN TECHNICAL FIELD OF THE INVENTION

The present invention relates to phenolic resol type resins prepared by using polycyclic phenols and the production method thereof. The present invention relates to improving the characteristics of the phenolic resins used in abrasive emery sector, by using polycyclic phenols. By adding polycyclic phenols to the resin produced for emery in specific conditions and formulations, it has been enabled to provide elasticity to emery cloth or emery paper. STATE OF THE ART

The resins of the present invention are prepared for the use in the production of cloth or paper emeries in the abrasive emery sector. The emeries manufactured with the phenolic resole type resins which are prepared by using the polycyclic phenols of the present invention have elastic characteristic.

In the abrasive sector, a highly rigid structure is formed when the cloth or paper emeries are covered with a phenolic resin known in the state of the art. Thus, cracks are observed when the cloth or paper emery is folded or curled. The emeries which are used manually or which are inserted in machines are used by curling.

The emeries manufactured with the resins known in the state of the art are not elastic. Cracks and chippings are formed when the cloth or paper emeries used manually or in machines are buckled or folded and these can not be used since the broken parts can not be inserted in the machine again. The emery either continues to abrade but can not be used because parts fall off or break, or it loses its abrasive features due to the fact that the abrasives which provide the abrasive characteristic fall off. In other words, the emeries become dysfunctional before their shelf lives without losing their useful condition. The emeries prepared with the resins of the present invention have elastic characteristics. The resins prepared with polycyclic phenols are used in various sectors, in various forms. These resins are used for improving water impermeability in chipboard sector, for decreasing the free formaldehyde values in manufacturing children's furniture and for plywood production. However in these manufacturing processes, polycyclic phenols are added as additives after the resins are completed physically. In other words, a production is performed where the said effect of the polycyclic phenol and the effect of the resin seem to be physically combined. In the product of the present invention, the reactive structure of the polycyclic phenol derivatives have been utilized and a new characteristic which did not exist in the previous ones have been created for the resin by forming a copolymer or numerous various polymeric structures during the manufacturing process of the resin. Generally the emery manufacturers ovendry the paper or cloth after covering with resin and abrasive material for a pre-curing in order to obtain emery in their systems, wherein the temperature of the oven is about 120 ^° C. When the resins of the present invention are utilized, temperature in question has been reduced to about 85-90 ^° C or the same temperature is preserved but the time is shortened and the speed of the band is increased. In other words, because of the gel time of the resin of the present invention being shorter from the gel time of the resins known in the state of the art, both temperature and time are saved during the production. While the gel time of the resins used in the state of the art is approximately 45 mins at about 100 ^° C, the gel time of the phenol resins of the present invention is 12 mins at 120 ^° C.

BRIEF DESCRIPTION OF THE INVENTION

The objective of the present invention is to develop phenolic resol type resins using polycyclic phenols. These phenolic type resins are appropriate for use in the abrasive sector.

Another objective of the present invention is to make the emery elastic by using phenolic resol type resins which are prepared with polycyclic phenols. Emery papers or cloths are produced by using the phenolic resins which include polycyclic phenols of the present invention. By adding polycyclic phenols to the resin produced for emery in specific conditions and formulations, it has been enabled to provide elasticity.

DETAILED DESCRIPTION OF THE INVENTION

The objective of the present invention is to develop phenolic resol type resins used in the abrasive sector, by utilizing polycyclic phenols.

The present invention is related to the production method of the phenolic resol type resins prepared by utilizing polycyclic phenols.

In the present invention, emery cloths or papers are manufactured by using phenolic resins which include polycyclic phenols. These emery papers or cloths which are produced in this way have highly elastic characteristic.

In the present invention, elasticity has been provided to cloth or paper emeries by making a modification on the resin used during their preparation. By adding polycyclic phenols to the resin produced for emery in specific conditions and formulations, it has been enabled to provide elasticity. Furthermore, changes have been made in the emery production conditions when compared to the known state of the art. When the phenolic resin produced via the process of the present invention is used in emery production, capacity has been increased by shortening the emery production time; or energy has been saved by decreasing the curing temperature and the emery production capacity has been increased.

The polycyclic phenols used in phenolic resin production in the present invention are natural extracts obtained from trees, such as acorn tree extract.

In the present invention a new method is used for the production of phenolic resins which include polycyclic phenols. First of all, sufficient amounts of phenol, sodium hydroxide (NaOH), paraformaldehyde and methanol (Met-OH) are loaded into the reactor. The temperature is increased up to 60 - 65 ^° C. 60 - 90 minutes pass in 60 - 65 ^° C. The temperature is decreased down to 55 ^° C and a sufficient amount of NaOH is added. The temperature is increased up to 90 ^° C. The mixture is kept between 30 minutes - 3 hours at this temperature. A sufficient amount of urea, a sufficient amount of polycyclic phenol, preferably 1.0 - 40 kg, and water is added. The temperature is decreased down to 55 ^° C and vacuum distillation starts. Diethylenglycol is added and the material which has the appropriate viscosity is unloaded.

Approximately 45 - 47 % phenol, approximately 0.5 - 0,8 % NaOH, approximately 23 - 24 % paraformaldehyde, approximately 0,35 - 0,55 % Met-OH is used during production. The amount of urea is approximately 0.15 - 0.40 % and approximately 10 % water is used.

The resin which is obtained according to the method above has a viscosity of 1800 - 2400 cp at 25 ^° C. The pH value is approximately 8,6 - 9,4 and the density is approximately 1 ,24 - 1 ,27 g/cm ³ at 20 ^° C. Gel time is approximately 35 - 42 minutes at 100 ^° C.