Phenolic friction particles

Claim 1

In a process for the production of substantially completely cured resin friction particles the essential steps of: (A) reacting, in an aqueous medium at a temperature of from about 50° C. to about 100° C., (I) a mixture of phenols, said mixture comprised of from 25 to 100 mole percent of tri-and/or tetrafunctional phenols and from 0 to 75 mole percent of difunctional phenols; (II) from 1.1 to 3 moles per mole of phenol moiety of an aldehyde containing from 1 to 11 carbon atoms, (III) from 0.01 to 1 mole per mole of phenol moiety of a reaction promoting compound chosen from the group of alkali and alkaline earth hydroxides and oxides and the primary, secondary and tertiary amines having up to 10 carbon atoms and (IV) from 0.05 to 6 weight percent of a protective colloid based on the weight of compounds (I), (II) and (III); for a period of time such that a particulate, heat reactive, and substantially water-insoluble phenol resin is formed which is dispersed in said aqueous medium; (B) adding an acid compound to the aqueous dispersion of step (A) in an amount such that the pH of the aqueous dispersion is from 0 to 4, and substantially completely curing the resin particles, and (C) separating the resin particles from the aqueous medium.