A continuous fiber brake rotor preform and apparatuses and methods for manufacturing the preform are disclosed herein. The preform comprises a plurality of continuous fiber streams or filaments forming a substantially helical structure having layers or flights compressed together in the preform's longitudinal direction. Each continuous fiber stream or filament may comprise the same or different types of fiber, extends substantially between longitudinally disposed preform ends, and resides laterally adjacent to another continuous fiber stream or filament within each layer or flight of the helical structure. The radial distance between each continuous fiber stream or filament and the preform's longitudinal axis varies with angular location about the longitudinal axis. The preform further comprises web or z-direction fiber interspersed within the helical structure with certain of the web or z-direction fibers and continuous fiber streams or filaments extending at least partially in the longitudinal direction between the preform's layers or flights.

The present invention concerns a shaped composite material and a method for producing it. More specifically, the invention concerns a disc for a disc brake made from ceramic composite materials, usually known as CMC, i.e. Carbon Material Ceramic or CCM, i.e. Carbon Ceramic Material. These materials consist of carbon matrices containing carbon fibres usually infiltrated with silicon and a product of reaction between C and Si, silicon carbide (SiC). More specifically, the invention concerns a shaped composite material comprising a inner layer (3; 103) of CCM C/SiC/Si material comprising disorderly short filaments consisting mainly of carbon and respective outer layers (2, 2; 102, 102) of C/SiC/Si material and having an orderly fabric structure of mainly carbon fibres.

A coating arrangement has the following characteristics: particles having a scratch hardness greater than or equal to 9 and a median grain size that can be determined, a coating having a thickness equaling approximately half the median grain size, a coating carrier with a surface comprising recesses, wherein a portion greater than 85% of the recesses compared to a surface surrounding the associated recess is designed with a depth smaller than approximately 10% and/or a opening width smaller than or equal to approximately 15% of the coating thickness, and the coating is applied to the surface of the coating carrier and surrounds the particles at least at a lower region oriented toward the coating carrier.

In a dry friction material and a method for manufacturing the same, to maintain a content of glass fibers low on a whole dry friction material to apply a hole boring for caulking assembly with high strength and high stiffness at a part to be subjected to the hole boring. A part (glass-rich part 30) to be subjected to the hole boring is pressed at a higher pressure than a part not to be subjected to the hole boring in a press-shaping step by providing a rib 21 protruding toward a shaped body side on a part of press dies 20A, 20B corresponding to the part to be subjected to the hole boring. Thereby, only a compounded rubber 4 is pushed outward and only the glass-rich part 30 has an increase in a content of glass fibers 3. Thereby, strength that can withstand the hole boring is obtained. Accordingly, a dry friction material 1 with a bored hole 2 bored without generating a failure in the hole boring can be manufactured.