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Title:
A RESIN FOR ABRASIVE MATERIALS AND A PRODUCTION METHOD THEREOF
Document Type and Number:
WIPO Patent Application WO/2020/190238
Kind Code:
A2
Abstract:
With the present invention, there are developed a phenolic resin suitable for use especially in abrasives sector, a production method of said resin and a method for producing an abrasive material with said resin. The present invention provides abrasive materials which have a high elasticity coefficient and a long service life without getting deformed. The abrasives produced are suitable for use manually, in machines, or for other particular purposes, wherein the abrasives eliminate problems as tearing/breaking. While having flexible mechanical and thermal properties, the abrasive materials also have the property of being coloured, which is crucial for the sector.

Inventors:
CETIN HAYDAR (TR)
AKSIN ARTOK OZGE (TR)
GUVENDIK ALPER EMRE (TR)
OZCAN HANDE (TR)
Application Number:
PCT/TR2020/050198
Publication Date:
September 24, 2020
Filing Date:
March 11, 2020
Export Citation:
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Assignee:
CUKUROVA KIMYA ENDUSTRISI A S (TR)
International Classes:
B24D11/00
Attorney, Agent or Firm:
CAYLI, Hulya (TR)
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Claims:
CLAIMS

1. A resin suitable for use in abrasive materials, characterized by comprising at least one compound selected from phenol and/or derivatives thereof, at least one compound selected from aldehyde-based chemicals, at least one strong base, at least one fatty acid ester, at least one nitrogen-containing compound, at least one weak acid, at least one pH balancing agent, at least one plasticiser and at least one curing accelerating agent.

2. A resin according to claim 1 , characterized in that molar ratio of a compound selected from phenol and/or derivatives thereof to a compound selected from aldehyde-based chemicals is in the range of 0.8 to 3.0.

3. A resin according to claim 1 , characterized in that molar ratio of a compound selected from phenol and/or derivatives thereof to a compound selected from aldehyde-based chemicals is in the range of 1.0 to 2.3.

4. A resin according to claim 1 , characterized in that molar ratio of a compound selected from phenol and/or derivatives thereof to a compound selected from aldehyde-based chemicals is in the range of 1.2 to 1.7.

5. A resin according to claim 1 , characterized in that at least one compound selected from aldehyde-based chemicals comprises paraformaldehyde.

6. A resin according to claim 1 , characterized in that at least one strong base comprises sodium hydroxide.

7. A resin according to claim 1 , characterized in that at least one fatty acid ester comprises methyl esters of unsaturated fats, ethyl propyl, butyl esters of all fats and/or combinations thereof.

8. A resin according to claim 1 , characterized in that fatty acid esters are in the range of 0.1 % to 5% by weight based on the total weight.

9. A resin according to claim 1 , characterized in that at least one nitrogen-containing compound comprises urea, melamine, tannic acid and/or any combinations thereof.

10. A resin according to claim 1 , characterized in that at least one weak acid comprises salicylic acid, phthalic acid, weak phenolic acids and/or combinations thereof.

11. A resin according to claim 1 , characterized in that at least one weak acid comprises salicylic acid.

12. A resin according to claim 1 , characterized in that at least one pH balancing agent comprises tertiary amine, triol and/or combinations thereof.

13. A resin according to claim 1 , characterized in that at least one pH balancing agent comprises triethanolamine, dimethylethanolamine and/or combinations thereof.

14. A resin according to claim 1 , characterized by comprising coupling agents.

15. A resin according to claim 14, characterized in that the coupling agents comprise organosilane, silane derivatives with amino-functional group, silane derivatives with epoxy-functional group, silane derivatives with uredo-functional group and/or combinations thereof.

16. A resin according to claim 1 , characterized in that at least one plasticiser comprises polycyclic phenols, hydrogenated vegetable oils, plasticiser adipates, plasticiser phthalates, fatty esters, epoxide vegetable oil esters, glycols and glycol esters, mineral oils and derivatives thereof, polyesters, carboxymethylated cellulose and derivatives thereof, long chain alcohols, sodium naphthalene sulphonate, metyl oleate, phthalic anhydride, urea formaldehyde glues, polyvinyl alcohols with different hydroxyl percentages and polymer chain lengths and/or combinations thereof.

17. A resin according to claim 1 , characterized in that adipates comprise dioctyladipate, phthalates comprise dioctylterephthalate, glycols and glycol esters comprise polyethylene glycol, butyldiglycol and/or ethylene glycol.

18. A resin according to claim 1 , characterized in that the plasticiser comprises polyvinyl alcohol.

19. A resin according to claim 18, characterized in that an amount of the polyvinyl alcohol is in the range of 0.1% to 50% by weight based on the total weight.

20. A resin according to claim 18, characterized in that an amount of the polyvinyl alcohol is in the range of 0.2% to 20% by weight based on the total weight.

21. A resin according to claim 18, characterized in that an amount of the polyvinyl alcohol is in the range of 0.5% to 5% by weight based on the total weight.

22. A resin according to claim 18, characterized in that the polyvinyl alcohol is in solid form.

23. A resin according to claim 18, characterized in that the polyvinyl alcohol is in solution form.

24. A resin according to claim 23, characterized in that the polyvinyl alcohol is a 4% PVA solution with a viscosity value in the range between 3MPa.sn and 70MPa.sn.

25. A resin according to claim 1 , characterized in that the curing accelerating agent comprises propylene carbonate, lactones, aniline derivatives and/or combinations thereof.

26. A resin according to claim 1 , characterized in that the curing accelerating agent comprises gamabutyrolactone.

27. A resin according to claim 1 , characterized in that the curing agent comprises N-(2- hydroxyethyl)aniline.

28. A resin according to claim 27, characterized in that N-(2-hydroxyethyl)aniline is in the range of 1% to 2% by weight based on the total weight.

29. A production method of the resin suitable for use in abrasive materials, characterized by comprising the steps of:

- placing in a reactor/reaction vessel at least one compound selected from phenol and/or derivatives thereof together with at least one compound selected from aldehyde-based chemicals and at least one strong base to initiate the reaction;

- modifying the obtained mixture by adding at least one fatty acid ester;

- adding at least one nitrogen compound to the mixture;

- then, adding at least one weak acid;

- adjusting pH value by adding at least one pH balancing agent;

- adding at least one plasticiser and forming a polymer mixture;

- adding at least one curing accelerating agent, and obtaining the resin.

30. A method according to claim 29, characterized in that at least one compound selected from phenol and/or derivatives thereof and at least one compound selected from aldehyde-based chemicals are added such that the molar ratio is in the range of 0.8 to 3.0.

31. A method according to claim 29, characterized in that at least one compound selected from phenol and/or derivatives thereof and at least one compound selected from aldehyde-based chemicals are added such that the molar ratio is in the range of 1.0 to 2.3.

32. A method according to claim 29, characterized in that at least one compound selected from phenol and/or derivatives thereof and a compound selected from aldehyde- based chemicals are added such that the molar ratio is in the range of 1.2 to 1.7.

33. A method according to claim 29, characterized in that at least one compound selected from aldehyde-based chemicals comprises paraformaldehyde.

34. A method according to claim 29, characterized in that at least one strong base comprises sodium hydroxide.

35. A method according to claim 29, characterized in that at least one fatty acid ester comprises methyl esters of unsaturated fats, ethyl propyl, butyl esters of all fats and/or combinations thereof.

36. A method according to claim 35, characterized in that fatty acid esters are added in the range of 0.1 % to 5% by weight based on the total weight.

37. A method according to claim 29, characterized in that at least one nitrogen- containing compound comprises urea, melamine, tannic acid and/or any combinations thereof.

38. A method according to claim 29, characterized in that at least one nitrogen compound is added to the mixture when the viscosity value of the mixture is in the range of 100 cps - 70000 cps at 20°.

39. A method according to claim 29, characterized in that at least one nitrogen compound is added to the mixture when the viscosity value of the mixture is in the range of 500 cps - 4000 cps at 20°.

40. A method according to claim 29, characterized in that at least one weak acid comprises salicylic acid, phthalic acid, weak phenolic acids and/or combinations thereof.

41. A method according to claim 29, characterized in that at least one weak acid comprises salicylic acid.

42. A method according to claim 29, characterized in that at least one pH balancing agent comprises tertiary amine, triol and/or combinations thereof.

43. A method according to claim 29, characterized in that at least one pH balancing agent comprises triethanolamine, dimethylethanolamine and/or combinations thereof.

44. A method according to claim 29, characterized in that the coupling agents are added.

45. A method according to claim 44, characterized in that the coupling agents comprise organosilane, silane derivatives with amino-functional group, silane derivatives with epoxy-functional group, silane derivatives with uredo-functional group and/or combinations thereof.

46. A method according to claim 29, characterized in that at least one plasticiser comprises polycyclic phenols, hydrogenated vegetable oils, plasticiser adipates, plasticiser phthalates, fatty esters, epoxide vegetable oil esters, glycols and glycol esters, mineral oils and derivatives thereof, polyesters, carboxymethylated cellulose and derivatives thereof, long chain alcohols, sodium naphthalene sulphonate, metyl oleate, phthalic anhydride, urea formaldehyde glues, polyvinyl alcohols with different hydroxyl percentages and polymer chain lengths and/or combinations thereof.

47. A method according to claim 46, characterized in that adipates comprise dioctyladipate, phthalates comprise dioctylterephthalate, glycols and glycol esters comprise polyethylene glycol, butyldiglycol or ethylene glycol.

48. A method according to claim 29, characterized in that the plasticiser comprises polyvinyl alcohol.

49. A method according to claim 48, characterized in that the polyvinyl alcohol is added in the range of 0.1% to 50% by weight based on the total weight.

50. A method according to claim 48, characterized in that the polyvinyl alcohol is added in the range of 0.2% to 20% by weight based on the total weight.

51. A method according to claim 48, characterized in that the polyvinyl alcohol is in solid form.

52. A method according to claim 48, characterized in that the polyvinyl alcohol is in solution form.

53. A method according to claim 52, characterized in that the polyvinyl alcohol is a 4% PVA solution with a viscosity value in the range between 3MPa.sn and 70MPa.sn.

54. A method according to claim 29, characterized in that the PVA is added to the resin when the temperature of the resin is 40°C. 55. A production method of an abrasive material, characterized by comprising the steps of:

- applying the resin, which is prepared according to any of the claims 27 to 54, to the substrate/support onto which the abrasive grains hold;

- placing the abrasive grains onto the resin;

- curing the obtained abrasive material in a furnace.

Description:
A RESIN FOR ABRASIVE MATERIALS AND A PRODUCTION METHOD THEREOF

Technical Field

The present invention relates to resins giving flexibility and elasticity to the substrate/support on which abrasive grains are coated in order to obtain abrasive materials which are suitable for industrial, manual or individual use and maintain their abrasion properties for a long time, and a synthesis of these resins.

Backqround of the Invention

Abrasive materials are widely used in various industrial, domestic and technological applications. Due to different usage areas, the abrasive materials may have different physical and chemical compositions, and different shapes or sizes may be preferred according to said usage areas. Common uses of abrasive materials include grinding, polishing, cutting, drilling, sharpening and sanding. Since abrasive materials are able to be shaped for various purposes, they can be produced as blocks, straps, discs, wheels, plates, rods and loose grains. In addition to abrasive grains, abrasive materials comprise fillers and/or binding materials and/or a substrate/layer. As abrasive materials can have different shapes depending on their contents and production methods, they can be divided into two separate groups as bonded abrasive materials and coated abrasive materials. In the art, bonded abrasive materials are obtained by a mixture of abrasive grains with fillers and binding materials. In coated abrasive materials, on the other hand, abrasive grains are bonded or adhered to a substrate, such as in sandpapers. Here, the substrate may be a paper, a fabric, a vulcanized fibre or resin. According to surfaces and materials they are used on, abrasive grains may be different components, for example a glass, a flint, a garnet, aluminium oxide, silicon carbide. Since coated abrasive materials (e.g. sandpapers) produced according to methods known in the art are not flexible enough, breaks and spalls are observed following a folding/bending process. Insufficient flexibility of the substrates carrying the abrasive grains causes the abrasive materials to break, loose their abrasion properties and shortens their lifetime. Within the known state of art, an example in which phenolic resin is used as a binder together with the abrasive grains is disclosed in US2017129075 A1. Here, using aliphatic tack modifier and phenolic resin as a binding agent provides orientation of the abrasive grains. US20140318025 A1 aims to improve abrasion properties of the abrasive materials by utilising thiol groups. WO2012089351 discloses production of a resin which comprises polycyclic phenol for use in providing the abrasive materials with the property of flexibility. In this case, polycyclic phenols react with methanol and paraformaldehyde in presence of sodium hydroxide. However, formulations and production method disclosed in said documents do not provide the abrasive materials with sufficient elasticity and colouring. Brittle and rigid structure of the abrasive grains requires a high elasticity coefficient for the substrate (support) to which they are applied. For that reason, there is a need to develop a resin which provides the abrasive material with elasticity property and is capable of maintaining its abrasion function for a long time, and a production method thereof.

Brief Description of the Invention

With the present invention, there is provided a resin suitable for use in abrasive materials. The resin comprises at least one compound selected from phenol and/or derivatives thereof, at least one compound selected from aldehyde-based chemicals, at least one strong base, at least one fatty acid ester, at least one nitrogen-containing compound, at least one weak acid, at least one pH balancing agent, at least one plasticiser and at least one curing accelerating agent.

With the present invention, there is also provided a production method of the resin according to the invention. The method comprises the steps of: placing in a reactor/reaction vessel at least one compound selected from phenol and/or derivatives thereof together with at least one compound selected from aldehyde-based chemicals and at least one strong base to initiate the reaction; modifying the obtained mixture by adding at least one fatty acid ester; adding at least one nitrogen compound to the mixture; then, adding at least one weak acid; adjusting pH value by adding at least one pH balancing agent; adding at least one plasticiser and forming a polymer mixture; adding at least one curing accelerating agent and obtaining the resin. Because the abrasive materials are rigid and they are not provided with a desired flexibility during production, problems as breaking, reduction in abrasion properties and loss of flexibility occur frequently during abrasion processes. With the present invention, there are developed a resin, which eliminates said problems and is provided with elasticity property, and abrasive materials produced with said resin.

Object of the Invention

An object of the present invention is to develop a resin comprising phenol formaldehyde for maintaining the abrasion property of the abrasive material for a long time and giving elasticity to the substrate to which brittle rigid abrasive grains are bonded, and a production method.

Another object of the present invention is to develop a resin comprising phenol formaldehyde for providing colour stabilization of the abrasive materials and facilitating the application thereof, and a production method.

Yet a further object of the present invention is to develop a production method of a resin comprising phenol formaldehyde which is resistant to breaking and deformation for binding the abrasive grains firmly to the substrate/surface and/or support.

Description of the Invention

Abrasive grains should be used by providing flexibility in order to be suitable for use manually, in machines, or for other particular purposes. Substrate which is used to provide the abrasive grains with flexibility and to hold the abrasive grains together may be a woven fabric, a paper, a fibre or resin. Resin-based substrates produced according to the conventional methods may cause harder and more brittle abrasive materials to be obtained, instead of providing the abrasive grains with flexibility. For that reason, with the present invention, there is developed a resin comprising phenol formaldehyde for maintaining the abrasion property of the abrasive material for a long time and giving elasticity to the substrate to which brittle and rigid abrasive grains are bonded, and a production method. The resin according to the present invention comprises at least one compound selected from phenol and/or derivatives thereof, at least one compound selected from aldehyde- based chemicals, at least one strong base, at least one fatty acid ester, at least one nitrogen-containing compound, at least one weak acid, at least one pH balancing agent, at least one plasticiser and at least one curing accelerating agent.

The production method of the resin according to the present invention comprises the steps of: placing in a reactor/reaction vessel at least one compound selected from phenol and/or derivatives thereof together with at least one compound selected from aldehyde- based chemicals and at least one strong base to initiate the reaction; modifying the obtained mixture by adding at least one fatty acid ester; adding at least one nitrogen compound to the mixture; then, adding at least one weak acid; adjusting pH value by adding at least one pH balancing agent; adding at least one plasticiser and forming a polymer mixture; and adding at least one curing accelerating agent and obtaining the resin.

A production method of the abrasive materials comprising the resin according to the present invention comprises the steps of: placing in a reactor/reaction vessel at least one compound selected from phenol and/or derivatives thereof together with at least one compound selected from aldehyde-based chemicals and at least one strong base to initiate the reaction; modifying the obtained mixture by adding at least one fatty acid ester; adding at least one nitrogen compound to the mixture; then, adding at least one weak acid; adjusting pH value by adding at least one pH balancing agent; adding at least one plasticiser and forming a polymer mixture; adding at least one curing accelerating agent; after preparation of the resin with the added compounds, applying the resin to the substrate/support onto which the abrasive grains hold; placing the abrasive grains onto the resin; curing the obtained resinous abrasive grains in a furnace and obtaining the abrasive material.

In a preferred embodiment of the present invention, molar ratio of at least one compound selected from phenol and/or derivatives thereof to at least one compound selected from aldehyde-based chemicals is in the range of 0.8 to 3.0 (preferably in the range of 1.0 to 2.3, more preferably in the range of 1.2 to 1.7). In another preferred embodiment of the present invention, the aldehyde-based chemical preferably comprises paraformaldehyde.

In another preferred embodiment of the present invention, the at least one strong base comprises sodium hydroxide. In this case, the strong base functions as a catalyst. The strong base is preferably added to the resin according to the invention in a single step or two separate steps. A portion of the catalyst is added to the mixture before initiation of the exothermic reaction, and the remaining portion thereof is added 15 minutes after the initiation of said exothermic reaction, i.e. when the exothermic reaction is more controllable. In each step, the strong base is preferably added in a range of 0.003 to 0.3 of the total mole amount of at least one compound selected from phenol and/or derivatives thereof. If a lower amount of strong base is added, it cannot function as a catalyst in the resin mixture as desired, while excess usage affects the mechanical properties and colour of the resin in a negative manner.

In a preferred embodiment of the present invention, at least one fatty acid ester that is added comprises methyl esters of unsaturated fats and/or ethyl propyl, butyl esters of all fats. Said fatty acid esters are used with a ratio in the range of 0.1% to 5% by weight based on the total weight of the resin. Addition of fatty acid esters with this ratio saponifies some of the catalyst in the resin. Saponification decelerates the reaction which is required for generating the resin while it contributes the resin to have a more flexible structure. Fatty acid esters added in this step create a surfactant effect that ensures both the application of the resin to the support and the application of abrasive grains to the resin homogeneously.

In a preferred embodiment of the present invention, the at least one nitrogen-containing compound comprises urea, melamine, tannic acid and/or any combinations thereof. Using nitrogen compounds in this case allows free formaldehydes in the resin to be captured. In order for the developed resin to be in the desired colour, said formaldehyde capturing component preferably comprises an amino-functional group. The abrasive material obtained with the resin according to the invention can be coloured and has flexible mechanical properties. In a preferred embodiment of the present invention, the at least one nitrogen compound is added to the mixture when the viscosity value of the mixture is in the range of 100 cps - 70000 cps (more preferably 500 cps - 4000 cps) at 20°. Said ideal viscosity value is obtained in a temperature range of 60°C to 100°C by preferably increasing 1 °C per minute, with a waiting time of 30 minutes at 90 °C.

In an alternative embodiment of the present invention, at least one weak acid that is added comprises salicylic acid, phthalic acid, weak phenolic acids and/or any combinations thereof (preferably salicylic acid). In this case, the weak acids are added for ion exchange with strong bases that cause the colour of the resin to darken. Weak acids are preferably added to the mixture in the same molar ratio with the strong bases. Therefore, negativities caused by acids of the weak bases (such as NH 4 CI, NH 4 N0 3 and such ammonium salts) used in conventional methods such as bad odour due to ammonia release and decrease in the water tolerance of the resin which makes it difficult to mix with water, are eliminated. Resin deliquescence and bad odour occurrence problems which are frequently encountered in the art are solved by the resin and the production method of the invention.

In a preferred embodiment of the present invention, at least one pH balancing agent that is added comprises tertiary amine, triol and/or combinations thereof. The pH balancing agent preferably comprises triethanolamine (TEOA), dimethylethanolamine (DMEOA) and/or combinations thereof. The pH balancing agents balance the pH of the resin and function as a second catalyst. As the pH balancing agents are odourless organic bases, they solve bad odour problem occurred in the resin and help the resin have an odourless and flexible structure.

In the method according to the invention, additional base can preferably be added to adjust pH based on a type of the surface on which the resin is applied. Resins with acidic pH are suitable if the substrate/support to which the resin is applied is wool-, polyamide-, silk-based etc., and resins with basic pH are suitable for cotton-, ketene-, cellulose-based surfaces. Since the resin and the substrate comply with each other thanks to this method, binding of the resin to the substrate/support is improved. In another preferred embodiment of the invention, the resin according to the invention comprises at least one coupling agent. In this case, the at least one coupling agent may comprise organosilane, silane derivatives with amino-functional group, silane derivatives with epoxy-functional group, silane derivatives with uredo-functional group or any combinations thereof.

In a preferred embodiment of the present invention, at least one plasticiser agent comprises phenols, hydrogenated vegetable oils, plasticiser adipates (e.g. dioctyladipate), plasticiser phthalates (e.g. dioctylterephthalate), fatty esters, epoxide vegetable oil esters, glycols and glycol esters (e.g. polyethylene glycol (PEG), diethylene glycol (DEG), butyldiglycol DB), mineral oils and derivatives thereof, polyesters, carboxymethylated cellulose and derivatives thereof, long chain alcohols, sodium naphthalene sulphonate, metyl oleate, phthalic anhydride, urea formaldehyde glues, polyvinyl alcohols (PVA) with different hydroxyl percentages and polymer chain lengths and/or combinations thereof. Role of the plasticiser agent in the resin is crucial. Since the resin according to the invention is phenolic, at least one plasticiser agent preferably comprises polyvinyl alcohols (PVA) due to the vinyl groups and stretchable pi bonds of the resin. Polyvinyl alcohols (PVA) may be used alone or in combination with the other plasticisers described above. With the alcohol groups they have, polyvinyl alcohols comply with the phenolic hydroxyl groups in the resin and are homogeneously added to this phenolic structure with the hydrogen bonds. Hydrolysis number, polymer length, weight, purity and usage amount of the PVA directly affects the properties of the resin and the abrasive materials. Thus, it is of great importance to provide proper PVA modification. Usage amount of PVA for said modification is in the range of 0.1 % to 300 (preferably in the range of 0.2% to 20%, more preferably in the range of 0.5% to 5%) by weight based on the total weight. If the PVA character is desired to be dominant, usage amount of PVA is in the range of 50% to 300% by weight based on the total weight. Usage of higher amounts of PVA may cause repression in the thermal and mechanic properties arising from the phenolic polymer in the resin. Hydrolysis percentage of PVA is required to be high for said modification. Due to the high hydrolysis percentage, hydroxyl number of the phenolic structure in the resin increases, and better and more flexible hydrogen bonds are generated with electronegative groups of the fibres present on the surface. PVA chains with high hydrolysis percentages interact more with phenol formaldehyde polymer chains in the resin. With more interaction, a high compliance and curing are provided in the resin. For that reason, hydrolysis number per each mole in the resin according to the invention should be in the range of 50% to 99%. For ideal resins, PVA should be added to the resin preferably at 40°C. Here, 4% PVA solutions with a viscosity value in the range between 3MPa.sn and 70MPa.sn under DIN 53015 at 20°C are used. PVA is preferably dissolved in a different reactor and added in the last step of the resin production method. PVA, which may be in solid or solution form, is preferably added to the mixture so that its weight is 0.5% to 5% by weight based on the total weight. Another important factor is polymerisation degree. As the polymer length of PVA increases, it increases the viscosity of the resin to which it is added. Increase in the viscosity of resin causes problems during usage and causes non-compliance of the other materials, which are preferably added (e.g. fillers), to the resin. As the polymer length of PVA becomes shorter (having a low polymerisation degree), it does not provide the resin, to which it is added, with ideal binding property. Thus, the PVA should be added to the resin with abovementioned conditions and properties. If the PVA with the values described in the invention is added to the resin with the described values, the resin with perfect flexibility is obtained. Alcohol groups of PVA comply with the hydroxyl groups of the resin due to the phenolic structure of the resin. Therefore, PVA is added homogenously to the resin structure with hydrogen bonds. As a result of these synergistic actions, a polymer mixture is generated. The polymer mixture generated crosslinks with free formaldehydes in the resin structure during a firing process so that it has a water-insoluble, colourable and flexible property which satisfies thermal and mechanical resistance. Such flexibility enables the abrasive grains to be bonded strongly to the substrate/layer.

In another embodiment of the invention, at least one curing accelerating agent comprises propylene carbonate, lactones (preferably, gamabutyrolactone), aniline (and/or derivatives thereof) and/or combinations thereof. These components reduce the curing/gelling time of the resin. If compared to curing accelerating agents known in the art, the curing accelerating agents used for the method of the invention reduces the gelling time without negatively affecting the curing colour and decreasing the binding property of the resin. Using the curing/gelling agents of the invention instead of other alkali-containing carbonates known in the art provides a faster curing. In the method according to the present invention, the curing accelerating agent preferably comprises N-(2- hydroxyethyl)aniline. Therefore, it is seen that the curing/gelling time of the resin is reduced by 10% to 20% when compared to the conventional methods. Though the abrasive materials are widely used today, they become non-functional within a short period of time as they are not produced sufficiently flexible and durable. If one or some of the production steps and the resin of the invention are used, flexible abrasive materials are able to be obtained; however, they do not have as much synergistic action as the ones prepared by this method. The resin obtained according to the method of the present invention enables that the abrasive grains are ideally applied and the abrasive materials are ideally shaped. The resin of the invention enables the abrasive grains to be firmly bonded to the substrate/support, to be colourable, and to gain a structure that can flex without breaking/deforming. Furthermore, the resin can also be used in sandpapers and fabrics.

In alternative embodiments of the present invention, the resin can be mixed with a filler and/or other additives (e.g. a colour pigment) before being applied to the abrasive grains. When the substrates obtained by the resin and the resin production method of the present invention are tested through appropriate quality controls, it is seen that the substrate has the compatible specifications with the sector to be used. Since the resins cross-link at a binding temperature, abrasive materials are obtained in which the abrasive grains firmly hold onto the substrate/support.

In another embodiment of the present invention, another layer of resin can preferably be applied to the abrasive grains which are bonded to the substrate/support. The abrasive materials prepared as several layers are cured by being moved forward in furnaces at certain angles, which enables more durable abrasive materials (e.g. sandpaper) to be obtained. The obtained abrasive material may preferably be processed further. For example, top surface of the abrasive material can be coated with a new top layer by using a mixture that contains grinding auxiliaries, inert fillers, anti-static agents, lubricants, anti loading agents and mixtures thereof. Following the processes according to the present invention, the abrasive material acquires a whitish surface colour. This colour can be changed easily by using an appropriate colour pigment at the beginning of the method steps of the invention or during preparation of the resin. Because colour of the abrasive material represents many criteria in the industry (e.g. type of the abrasive grain), it can be coloured according to the conventional representative colours. The abrasive material obtained by the method of the present invention can be cut to a desired size, and can be used by rubbing manually or by means of a machine or any dedicated means in order to perform abrasion/sanding processes on the surfaces. Since the resin according to the present invention provides a high flexibility as compared to the ones known in the art, it performs abrasion process without breaking or being deformed during the rubbing process. Firm binding to the substrate/support enables the abrasive grains to be used for a long time without losing their properties. Apart from the industrial use, the abrasive materials according to the present invention are also advantageous on the surfaces such as wood in terms of personal usages for hobby purposes.