COMPOSITE SPRINGS

Abstract: A spring leaf 4 of composite fibre reinforced synthetic resin material has opposed end surfaces 8, 9 enclosed by a U-shaped bearing member 7 of abrasion resistant material adapted to be received in, for example, a vehicle hanger bracket. The bearing member 7 is secured by countersunk headed screws 19 and internally screw-threaded sleeves 18 engaged in holes 17 drilled through the opposed side pans (11, 14) of the bearing member and the leaf 4. Adhesive may also be applied. In one form, the bearing member comprises two L-shaped components 7′, 7″, secured together. A multi-­ leaf spring has the bearing member applied to the upper, longer leaf 4. The opposed side parts 10, 11 are of unequal lengths, the longer one, 11, lying along the upper surface 8 of the upper leaf and extending beyond the adjacent end of the leaf 3, below to assist load distribution to the lower leaf or leaves of the spring in use.

Description: COMPOSITE SPRINGS This invention relates to leaf springs made from composite fibre reinforced synthetic resin. materials, and more particularly is concerned with the provision and securing of a bearing member on an end of such a spring. The composite materials from which such springs are made do not have a particularly good resistance to abrasion and they also have limitations which necessitate special provision being made for mounting such springs, as for example on a vehicle. In a vehicle application an axle may be secured to the spring intermediate its ends. The spring may be provided with eye ends for pivotal attachment to the vehicle. In such a construction the eye ends serve to locate the axle. In an alternative construction the spring is provided with bearing members at its ends which in use of the spring are usually slidably received in hanger brackets on the vehicle, the axle normally being located by a pivotally mounted torque arm connected between the axle and the vehicle. This invention is concerned with the provision of such a bearing member. The present invention consists in a leaf spring comprising a spring leaf of composite fibre reinforced synthetic resin material having at an end thereof a bearing member of abrasion resistant material, characterised in that the bearing member encloses opposed surfacs of the spring leaf at said end and comprises a generally U-shaped member having opposed side parts which lie along the respective opposed surfaces and means secured the bearing member to the spring leaf. The bearing member may be of any suitable material which ill protect the spring leaf from damage due to abrasion by a member with which the spring leaf has bearing engagement in use, for example a spring hanger bracket. Such brackets conventionally are metallic and accordingly the bearing member will normally also be metallic. Where circumstances require it other suitable abrasion resistant material may possibly be used. The bearing member may include means to locate the spring leaf in a suspension hanger bracket. In this case the member may comprise a first, generally L-shaped, component having a first limb which lies along one of the said surfaces of the spring leaf and a second limb which is inclined to the first limb so as to lie across and extend beyond an end face at the said end of the spring leaf, and a second component which lies along the other said surface of the spring leaf and is secured to the second limb of the first component whereby the extended second limb of the first component provides an abutment adapted to engage a hanger bracket for the spring to prevent the spring from sliding out of the hanger bracket in use. The second component may also be generally L-shaped thereby providing a first limb which lies along the other said surface of the spring leaf and a second limb which lies along, and may be secured to, the second limb of the first component. That side part of the bearing member which lies along the surface of the spring leaf which is under tension when the spring is normally loaded may be longer than the side part of the bearing member which lies along the surface of the spring leaf which is under compression when the spring is normally loaded. Desirably the free end of the side part which lies along the tension side of the spring leaf is relieved, as by a chamfer or radius, so that it does not cause abrasion of the surface -of the spring leaf when the latter flexes. The opposed side parts of the bearing member may be so spaced relative to the said surfaces of the spring leaf as to permit the insertion of packing pieces between each surface and the corresponding side part of the bearing member. Such packing pieces may be of a flexible, creep resistant material, for example nylon; so as to eliminate fretting between the bearing member and the spring leaf. The present invention further consists in a leaf spring comprising a first spring leaf of composite fibre reinforced synthetic resin material having at an end thereof a bearing member of abrasion resistant material, characterised in that the first spring leaf is superposed on a second spring leaf of composite fibre reinforced synthetic material and is longer than the second spring leaf, the bearing member encloses opposed upper and lower surfaces of the first spring leaf at said end thereof, and in that the bearing member comprises a generally U-shaped member having opposed side parts of unequal lengths of which the longer side part lies along the upper surface of the first spring leaf and extends beyond the adjacent end of the second spring leaf, and means securing the bearing member to the first spring leaf. Embodiments of the invention will now be described by way of example with reference to the accompanying drawings, in which: Figure 1 is a side elevation showing one end of a three leaf spring according to the invention, Figure 2 is a plan view of the end of the spring of Figure 1, Figure 3 is a section on line 3-3 of Figure 1, Figure 4 is a side elevation showing one end of a single leaf spring in accordance with the present invention in a suspension hanger bracket, Figure 5 is a side elevation showing one end of a two leaf spring with modified securing means for the bearing member, and Figure 6 is a section on line 6-6 through the leaf spring of Figure 5 showing a modification. Referring to Figures 1 to 3 of the drawings, a leaf spring 1 comprises three superposed spring leaves 2, 3, 4 of composite fibre reinforced synthetic resin material which are constructed in a known manner and are clamped together (not shown). The spring leaves are separated by rubbing strips 5, for example of medium carbon steel, secured to the lower surface of each of the leaves 3, 4 and wear plates 6, for example of a polyamide, secured to the upper surfaces of the leaves 2, 3 in rubbing contact with the respective rubbing strips 5. The upper leaf 4 has opposed upper and lower surfaces 8, 9 at its end which are enclosed within a bearing member 7. The bearing member 7 comprises first and second L-shaped components 7' and 7" respectively. The first component 7' has a side part 11 which lies on the upper surface 8 and an end limb 12 which is substantially normal to the side part 11 and extends across and beyond the end face 13 of the leaf 4. The second component 7" has a first side part 14 which lies along the lower surface 9- and an end limb 15 which lies along the end limb 12 of the first component 7' and is secured to that end limb 12, as by welding, at 16. As can be seen in Figure 1, the end of the upper leaf 4 is received between the upper and lower side parts 11, 14 of the bearing member 7. Nylon packing pieces 10 are interposed between the adjacent respective side parts and upper and lower surfaces of the leaf 4. Two laterally spaced holes 17, Figure 3, are drilled through the side parts 11, 14, the packing pieces 10 and the leaf 4 between them. End portions 17' of the holes 17 in the side part 11, 14 are countersunk. An internally screw threaded, countersunk, headed sleeve 18 is inserted into each hole 17 from the underside of the bearing member and leaf and is secured with a countersunk head screw 19 inserted from the top of the bearing member and leaf, as best seen in Figure 3. The screws 19 are preferably locked with a suitable known thread locking adhesive. The bearing member 7 may be bonded, as by an adhesive, onto the end of the leaf 4. In use of the leaf spring 1 the bearing member 7, secured to the upper leaf 4, is longitudinally slidably received in a hanger bracket secured to a vehicle. The side parts 11, 14 provide abrasion resistant surfaces for the spring within the hanger bracket. The end limbs 12, 15 prevent the spring from sliding out of the hanger bracket. When the leaf spring is in use the weight of the vehicle is applied to the spring through the upper side part 11 of the bearing member which is of a size to spread the load along the end of the upper leaf 4 and to give support to that leaf. The upper side 11 extends beyond the ends of the lower leaves 2, 3 of the spring, as shown in Figure 1, so as to assist in distributing the load to all three leaves of the spring, and so that it is at no point solely applied to the leaf 4. This will not, of course, be the case with a single leaf spring. Only'once end of the leaf spring 1 has been shown but it will be appreciated that a similar bearing member may be secured to the other end of the upper leaf 4, or alternatively a bearing member such as shown in Figure 4. Referring now to Figure 4, a suspension hanger bracket 20 is secured to the underside of a vehicle (not shown). A torque arm 21 (only part of which is shown) is pivotally connected in known manner between the bracket 20 and a spring seat which is clamped to the centre of the spring and to which the vehicle axle is secured (also not shown). A spring leaf 22, for example in accordance with the upper leaf 4 of the leaf spring of the above-described embodiment illustrated by Figures 1 to 3, has a generally U-shaped bearing member 23 applied to the end which is shown. The bearing member 23, similarly to the bearing member 7 of the previous embodiment, has a long, upper side part 24 with a lightly chamfered or rounded end and a shorter, lower side part 25 which respectively support the surfaces of the leaf 23 which are subjected to tensile and compressive forces when the leaf spring is normally loaded in use. Packing pieces and securing means are not shown but may be similar to those described in respect of the previous embodiment. As will be seen from Figure 4, the suspension hanging bracket 21 has Åa bearing surface 26 against which the upper surface of the upper side part 24 of the bearing member 23 engages. By way of example only, the bearing member 23, and similarly the bearing member 7 of the previous embodiment, may conveniently be made of steel strip in accordance with BS 1449 Part 1: 1972 HS60, which has good abrasion resistance and weldability. The upper surface of the upper side part 24 may be locally hardened over that area which engages the bearing surface of the hanger bracket. Screws, not shown but which are preferably like the screws 19 of the previous embodiment, for securing the bearing member to the leaf 23, are located away from the bearing area. The spring leaf 22, and each of the spring leaves of the first described embodiment, may be built up from a number of laminates of fibre reinforced synthetic resin, and have a constant cross-section. As an alternative, the spring leaves may be produced using a pulforming technique in which fibres impregnated in resin are drawn through a die of constant cross-sectional area, are then formed to a desired shape and the curing is completed subsequently. The cross-sectional area of these spring leaves remains constant but the section varies such that each leaf has a relatively narrow but deep section in the middle and tapers towards its ends which each have a wide and shallow section. Referring now to Figure 5, a leaf spring 27, of which one end only is shown, comprises two superposed spring leaves 28, 29 of composite fibre reinforced synthetic resin material which are clamped together (not shown). The spring leaves are separated by a rubbing strip 30 secured at the lower surface of the upper leaf 29 and a wear plate 31 secured to the upper surface of the lower leaf 28 in rubbing contact with the rubbing strip 30. The upper leaf 29 has opposed upper and lower surfaces 32, 33 respectively which are enclosed at the end of the leaf within a bearing member 34. The bearing member 34 is generally similar to bearing member 7 of the first-described embodiment comprising first and second L-shaped components 34' and 34" respectively. It will be noted, however, that its second component 34" has a shorter side part 35, and the rubbing strip 30 extends to the end of the upper leaf 29 and is secured between the side part 35 and the lower surface 33 of the upper leaf by aligned shouldered bolts 36 and shouldered nuts 36' which secure the bearing member 34 to the end of the leaf 29. An upper side part 37 of the first L-shaped component 34' of the bearing member 34 is additionally secured to the upper leaf 29 by aligned bolts 38 and shouldered nuts 38'. It will be observed that these nuts 38' are recessed into the lower surface of the upper leaf 29 and their outside diameters are increased to spread the load within the leaf. A rounded end 39 of the upper side part 37 of the first component 34' will also be noted which is provided to avoid abrasion of the upper surface 32 when the leaf 29 flexes. The end of the leaf spring 29 is shown in a hanger bracket -40. As shown in Figure 6, the sides of the lower spring leaf 28 may be inclined normally towards the lower surface of the leaf, and the sides of the upper spring leaf 29 may be inclined inwardly towards the upper surface of that leaf. This is an optional arrangement which provides side clearance in the hanger bracket to allow for twisting of the spring. The taper may be of the order of 70 This is particularly useful where it is desired to replace a conventional steel spring with a composite spring in accordance with the invention without changing the hanger brackets, and it is desired to retain the maximum width for the composite spring to meet performance requirements.

Claims: CLAIMS 1. A leaf spring comprising a spring leaf (4, 22, 29) of composite fibre reinforced synthetic resin material having at an end thereof a bearing member (7, 24, 34) of abrasion resistant material, characterised in that the bearing member (7, 24, 34) encloses opposed surfaces (8, 9, 32, 33) of the spring leaf (4, 22, 29) at said end and comprises a generally U-shaped member having opposed side parts (11, 14, 25, 35, 37) which lie along the respective opposed surfaces (8, 9, 32, 33) and means (18, 19, 38, 38') securing the bearing member (7, 24, 34) to the spring leaf (4, 22, 29). 2. A leaf spring according to claim 1 characterised in that said side part (11, 24, 37) of the bearing member (7, 24, 34) which lies along the surface (8, 32) of the spring leaf (4, 22, 23) which will be under tension when the spring is normally loaded for use is longer than the other side part (14, 25, 35) of the bearing member (7, 24, 34) which lies along the surface (9, 33) of the spring leaf (4, 22, 29) which will be under compression when the spring is normally loaded for use. 3. A leaf spring comprising a first spring leaf (4, 29) of composite fibre reinforced synthetic resin material, having at an end thereof a bearing member (7, 24, 34) of abrasion resistant material, characterised in that the first spring leaf (4, 29) is superposed on a second spring leaf (3, 28) of composite fibre reinforced synthetic material and is longer than the second spring leaf (3, 28), the bearing member (7, 3z) encloses opposed upper and lower surfaces (8, 9, 32, 33) of the first spring leaf (4, 29) at said end thereof, and in that the bearing member (7, 34) comprises a (.lenerally U-shaped member having opposed side parts (11, 14, 35, 37) of unequal lengths.of which the longer side part (11, 37) lies along the upper surface (8, 32) of the first spring leaf (4, 29) and extends beyond the adjacent end of the second spring leaf (3, 28), and means (18, 19, 38, 38') securing the bearing member (7, 34) to the first spring leaf (4, 29). 4. A leaf spring according to claim 3 characteri#sed in that a rubbing strip (5, 30) .is secured to the lower surface (9, 33) of the first spring leaf (4, 29) between the shorter side part (1.4, 35) of the bearing member (7, 34) and the first spring leaf (4, 29) and extends beyond the adjacent end of the second spring leaf (3, 28) for co-operation# with a wear plate (6, 31) secured to the upper surface of the second spring leaf (3, 28) at said adjacent end. 5. A leaf spring according to any preceding claim characterised in that the bearing member (7, 34) comprises a first generally L-shaped component (7', 34') having a first limb (11, 37) which lies along one of said opposed surfaces (8, 32) and forms one of said side parts of the bearing member (7, 34) and a second limb (12) which is inclined relative to the first limb (11, 37) so as to lie across and extend beyond an end face at the said end of the spring leaf (4, 29) to which the bearing member (7, 34) is secured, and a second component (7", 34") which lies along the other of said opposed surfaces (9, 33) and forms the other one of said side parts of the bearing member (7, 34) and is secured to the second limb (12) of the first component (7', 34'), the extended portion of said second limb (12) of the first component (7', 34') providing an abutment adapted to engage a hanger bracket (40) for the. spring to prevent that end of the spring from sliding out of the hanger bracket t40) in use. 6. A leaf spring according to claim 5 characterised in that the second component (7", 34") of the bearing member (7, 34) is generally L-shaped, having a first limb (14, 35) which lies along the other of said opposed surfaces (9, 33) and a second limb (15) which is inclined relative to the first limb (14, 35) and extends so as to form the abutment jointly with the extended portion of the second limb (12) of the first component (7', 34'). 7. A leaf spring according to claim 5 or claim 6 characterised in that the or each second limb (12, 15) extends normal to the or each first limb (11, 14, 35). 8. A leaf spring according to any of claims 5 to 7 as dependent from claim 3 or claim 4 characterised in that the sides of the first spring leaf (29) at the end to which the bearing member (34) is secured are inclined inwardly towards the upper surface (32) of the first spring leaf (29), and the sides of the second spring leaf (28) at its adjacent end are inclined inwardly towards it lower surface, the arrangement being such as to provide clearance between the sides of the leaves t29, 28) and a hanger bracket (40) with which the leaf spring is engaged in use and enable the spring to twist in the hanger bracket (40). 9. A leaf spring according to any preceding claim characterised in that a free end (39) of that side part (37) of the bearing member (34) which lies along the surface (32) of the spring leaf (29) which will be under tension when the leaf spring is in use and normally loaded, is relieved as by a chamfer or radius so as not to cause abrasion of the spring leaf (29) when flexing in use. 10. A leaf spring according to any preceding claim characterised in that a packing piece (10) of flexible creep resistant material is interposed and retained between at least one of the opposed surfaces (8, 9) of the spring leaf (4) and the adjacent side part (11, 14) of the bearing member (7)

Inventors: BENTLEY, ANDREW, HARDING, KEITH, WARD, TERENCE HENRY
Applicants: RUBERY OWEN HOLDINGS LIMITED
Application year: 1983
Main classification: B60G11
IPC codes: B60G11, F16F1