Patent ID: 7857294

Claim:
A composite spring comprising: a core; and multiple layers of a cured resin-impregnated composite fiber wound around the core, wherein the core and the multiple layers of cured resin-impregnated composite fiber form a spring having a desired helical pitch, diameter and spring rate; and wherein the multiple layers of cured resin-impregnated composite fiber are formed on the core by (a) rotating a straight form of the core at a desired rate and wherein fiber is pulled from spools and impregnated with resin as the spools travel linearly at a desired rate with respect to the longitudinal axis of the straight form of the core so as to allow each layer of the resin-impregnated composite fiber to be laid down in accordance with desired angles, and (b) the straight form of the core with resin-impregnated composite fiber is wrapped on a spring form and allowed to cure, and (c) the spring form is removed from the cured resin-impregnated composite fiber.