Pacific Coast Composites

David C Gordon, Jr

Edward D Pilpel

D Michael Gordon

Frank Meatto

A hybrid leaf spring includes an elongated primary leaf having a compression surface, an opposite tension surface, and a first modulus of elasticity. At least one composite material layer is provided having a second modulus of elasticity different from the first modulus of elasticity. An adhesive layer is interposed between and bonds the at least one composite material layer to and in substantially parallel relationship with a respective one of the tension and compression surfaces of the elongated primary leaf. A reinforcing layer of natural, synthetic or metallic sheet material extends within the adhesive layer, preferably in spaced relation to opposing surfaces of the primary leaf and the composite material layer to strengthen the bond formed by the adhesive layer.

Hybrid leaf spring with reinforced bond lines

In a method for making a hybrid leaf spring, at least one layer of composite material is molded onto a primary leaf using a mold with an interior cavity having a curvature for receiving the primary leaf at a depressed camber relative to its initial camber. The depressed camber is between unloaded and curb load cambers of the hybrid leaf spring. The primary leaf and the layer of composite material are positioned in the mold adjacent to one another and with a layer of adhesive therebetween. The layer of adhesive is cured for bonding together the primary leaf and the layer of composite material at the depressed camber so as to generally eliminate bond line shear stress when the camber of the hybrid leaf spring is at the curb height.

Method for producing a hybrid leaf spring

In a method for making a hybrid leaf spring at least one layer of composite material is provided and a metal primary leaf. The layer of composite material and metal primary leaf are positioned adjacent one another in a mold having an interior cavity defined by at least one cavity wall. A layer of adhesive material is located between and in engagement with the layer of composite material and the metal primary leaf. The adhesive is cured by controllably heating the metal primary leaf so that energy in the form of heat is conducted therefrom into the adhesive layer bonding said metal primary leaf and layer of composite material together.

Method of producing a hybrid leaf spring

In a hybrid leaf spring, an elongated primary leaf element is provided having a first modulus of elasticity, a tension surface, and a compression surface. At least one layer of composite material is substantially parallel to and bonded to the tension surface of the primary leaf element with at least a second layer of composite material bonded to the compression surface of the primary leaf. The primary leaf element can also include mounting eyes coupled to the ends of the primary leaf element for mounting the hybrid leaf spring to the frame of a vehicle. The hybrid leaf spring can also include multiple layers of composite material bonded to both the tension and compression surfaces of the primary leaf spring.

Growing community of inventors

Vista, CA, United States of America

David C Gordon, Jr