Importance

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Abstract

A composite leaf spring for use in a vehicle suspension system having a pair of metal outer skins and a stiff plastic core bonded between the skins. The core can be made of any one of a variety of filled or unfilled polymers which has a relatively high shearing strength and sufficiently isotropic properties so as to handle stresses in all directions. An important aspect of the invention is that it provides for a simple and inexpensive method for manufacturing a contoured composite leaf spring which includes the steps of first positioning the skins in a spaced relation within a female mold and then pouring or injecting the core material into the space between the skins. Preferably, the skins are of uniform width and thickness to reduce manufacturing costs. In most common vehicle applications, the spring would have a point of maximum thickness in the central section where the bending moment is greatest and would be tapered toward each end. The spring skins should meet the following criterion: if F equals the static loaded force (in lbs) exerted on the spring, which is supported at its ends; L equals the length of the spring (in inches) between the end supports; N equals the number of composite leaves in the spring (each leave comprising two skins bonded to a core); and T.sub.s equals the thickness (in inches) of each skin in each composite leaf; then: T.sub.s .gtoreq.(FL/N).sup.1/2 /1500.

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First Claim