Leaf-Spring

The present invention relates to a leaf-spring. More particularly, it relates to a leaf-spring which is composed of a fiber-reinforced duroplastic synthetic material, and which is clamped to a saddle of a vehicle axle by means of briden-type connecting elements (screws or brackets) and a clamping plate. In such springs there is a danger that the high pressure in the region of the axle clamping leads after a certain time to settling of the spring set, and thereby to loosening of the connecting elements. Moreover, the surfaces of the spring leaves can be damaged on the clamping edges in vehicle travel when the leaf-spring is subjected to alternating stresses, and during vehicle starting and braking, as a result of small relative movements between the spring leaves and the surfaces of the clamping elements, as well as during the movements of the spring leaves relative to one another.

Accordingly, it is an object of the invention to provide a leaf-spring which avoids the disadvantages of the prior art.

More particularly, it is an object of the present invention to provide a leaf-spring which makes possible transmission of the static and dynamic spring forces and moments from the axle to the spring leaf or spring leaves, without causing settling or damage to the spring set in the region of the axle clamping. In this manner loosening of the connecting elements, displacement of the spring leaves on the axle saddle and destruction of the spring are avoided.

In keeping with these objects and with others which will become apparent hereinafter, one feature of the present invention resides, briefly stated, in that the supporting plates are provided between the axle saddle and the leaf spring, between the clamping plate and the leaf-spring, and between the individual leaves of the leaf spring. The length of the supporting plates is greater than the length of the axle saddle and the clamping plate; also the supporting plates lie in the inner region between the connecting elements, and directly on the fiber-reinforced duroplastic synthetic material of the spring leaf, while in the outer region outside the connecting elements they are connected with the surfaces of the spring leaves through pressure cushions of a rubber-elastic material.

Due to the supporting plates being positioned in the entire region between the connecting elements and directly on the fiber-reinforced duroplastic synthetic material,- which is very pressure-resistant, particularly in the presence of a certain proportion of fibers extending transverse to the longitudinal direction of the spring, - the available pressure surface is used for clamping of the axle in an optimal manner, so that a minimal relaxation of the synthetic plastic spring in the region of its clamping with the vehicle axle is to be expected. The extension of the supporting plates beyond the region of the axle clamping provides a greater basis for pairs of forces resulting from starting and braking moments, and thereby a reduction of the forces which additionally act upon the spring surfaces at the clamping edges.

The interposition of the rubber-pressure cushion additionally prevents damage to the surfaces of leaves at the clamping edges, because of the relative movements between the spring leaves and the supporting plates in the longitudinal direction of the spring, when it is subjected to alternating stresses. Moreover, due to the extended region of the axle clamping, the rubber pressure cushions uniformly distribute the forces, which arise at the clamping edges, over the surfaces of the leaves. Hence the movability of the leaves during a spring movement or spring stroke is not unnecessarily impaired.

The supporting plate located between the clamping plate and the leaf spring is advantageously convex at its side facing the clamping plate in the region between the connecting elements. It it is formed here with a slight curvature toward the clamping plate, so that during tightening of the connecting screws it acts more strongly upon the central part of the clamping region. Thereby, the pressure loading of the synthetic plastic spring is distributed in the region of the axle clamping uniformly over the entire pressing surface and reduced to an absolute minimum. In particular, the pressure peaks are reduced in the region under the connecting elements. Thereby settling in the synthetic plastic material is avoided, which otherwise can lead to a loosening of the clamping with the axle saddle and as a result to a displacement of the spring relative to the axle.

The supporting plates can be composed, for example, of metal or a fiber-reinforced duroplastic synthetic material. In the clamping region inside the connecting elements the supporting plates are advantageously firmly and adhesively connected to the fiber-reinforced synthetic plastic of the spring leaves. Such adherence of the supporting plates to the spring leaves with the aid of glueing ensures, first of all, that the spring set is assembled as a spatial unit and individual parts are fixed relative to one another.

Preferably the upper pressure cushions outside the connecting elements are firmly and adhesively connected to the supporting plates and to the surfaces of the spring leaves by vulcanization or glueing. This also contributes to the firm assembly of the spring set. It is, however, even more noteworthy that as a result of these features, the pressure resistance of the rubber cushion, and thereby its effectiveness for absorbing forces caused by starting and braking moments is increased. Otherwise the pressure forces would, after a certain time, result in the rubber creeping out from the region of the supporting plates.

Preferably the pressure cushions arranged between the supporting plates and the surfaces of the spring leaves are pre-tensioned. The pre tensioning of the rubber pressure cushions increases their efficiency in taking up of forces caused by starting and braking moments. It unloads and simultaneously protects the fiber-reinforced synthetic plastic material from damage in the regions under the connecting elements.

The fiber-reinforced duroplastic synthetic material of the spring leaves is formed preferably as a bearing laminate which absorbs static and dynamic spring forces and moments. Non-bearing protective layers are arranged on the upper and lower side of the bearing laminate of the spring leaves, preferably in the region of clamping with the axle saddle. The protective layers can also be composed of a fiber-reinforced duroplastic synthetic material. The covering of the bearing laminates, --which are substantially longitudinally oriented laminates of the spring leaves, --by non-bearing protective layers of the fiber-reinforced synthetic plastic material in the region of the axle clamping is required under certain circumstances. It is required, first of all, when due to manufacturing, optical and durability grounds thermoplastic cover layers normally available for increasing the pressure strength of the spring set in the region inside the connecting elements are to be removed. Such removal can take place, for example by milling, without at the same time damaging the bearing laminate. The protective layers can be reinforced for obtaining the significant pressure strength, for example by an arrangement of short fibers, or by arranging long fibers to cross transversely at a 45.degree. angle relative to the longitudinal direction of the spring.

Moreover, the pressure forces of the briden clamping with the connecting elements are uniformly distributed by means of the interposition of the protective layers of fiber compound material, which does not contribute to the spring action. Consequently these forces are uniformly distributed, and therefore transmitted to the bearing laminate in a more protective manner. This effect can be further intensified by complete or partial filling of the milled-out layers with non-bearing fiber-reinforced synthetic plastic material. This makes it possible to avoid even the smallest longitudinal displacements between the supporting plates and the bearing laminate, --which normally take place also in the event of firm clamping of the spring set with the axle saddle at the edge of the direct clamping region under the connecting elements, --when the spring set is subjected to alternating stress. Such displacements can otherwise destroy the high loaded edge fibers of the bearing laminate.

For manufacture of the inventive leaf spring, it is preferable first to remove completely the through-going thermoplastic cover layers, and to remove partially the fiber-reinforced duroplastic protective layers by milling in the clamping region inside the connecting elements on the upper and lower sides of the spring leaves, and optionally to again reinforce the protective layers by glueing of fiber compound material. The spring leaves are then connected by glueing to the supporting plates, the latter having been provided with pressure cushions of the rubber-elastic material, which have already been vulcanized or glued onto the supporting plates.

By the milling-out of the thermoplastic cover layer, and of a part of the fiber-reinforced duroplastic protective layer over a length which corresponds to the part of the respective supporting plate facing the spring leaf, the additional advantage is obtained in that a certain form-locking effect is attained between the spring leaves and the clamping parts. This is advantageous for centering and fixation of the spring set on the axle saddle.

The bearing laminate does not have to be drilled, which is advantageous for the long service life of the leaf spring of the fiber-reinforced synthetic plastic material.

The novel features of the present invention are set forth in particular in the appended claims. The invention itself, however, as to its construction and method of manufacture will be best understood from the following description of preferred embodiments, which is accompanied by the following drawings.

FIG. 1 is a side view of a single leaf spring of the fiber-reinforced synthetic plastic material, which provides a connection with a vehicle axle, in accordance with the present invention; and

FIG. 2 is a longitudinal section of the region of axle clamping of a double leaf spring of a fiber-reinforced synthetic plastic material in accordance with the present invention, wherein the spring set includes a main spring leaf and an additional leaf spring.

A single leaf spring 1 shown in FIG. 1 is arranged on a vehicle axle 3 by means of an axle saddle 2. Briden-like connecting elements 4 in the form of screws are used for mounting the single leaf spring 1 on the axle saddle 2. The connecting elements 4 extend through aligned openings of the axle saddle 2 and a clamping plate 5 arranged above it, and they are fixed by nuts threaded on the screws. A lower supporting plate 6 lies on the axle saddle 2, and is arranged between the axle saddle 2 and the single leaf spring 1. An upper supporting plate 7 lies on the single leaf spring 1, and is arranged between the single leaf spring 1, and the clamping plate 5.

The supporting plates 6 and 7 are longer than the axle saddle 2 and clamping plate 5 in the longitudinal direction of the spring. In the region inside the connecting elements 4, they abut directly against the fiber-reinforced synthetic plastic material of the single leaf spring 1. The supporting plates 6 and 7 can be composed for example of metal or fiber-reinforced duroplastic synthetic material. The supporting plates 6 and 7 are thinner in the region located outside the connecting elements 4 than in the region located inside the connecting elements 4. A pressure cushion 8 is located between each thinner part of each supporting plate 6 and 7, on the one hand, and the lower or upper surface of the single leaf spring 1, respectively, on the other hand. The pressure cushion 8 is composed of a rubber-elastic material which can be pre-tensioned.

The single leaf spring 1 is composed essentially of a bearing laminate 9 of fiber-reinforced duroplastic synthetic material, which absorbs the static and dynamic spring forces and moments. A non-bearing protective layer 14 is arranged on the upper side and the lower side of the bearing laminate 9 within the pre-tensioned region of the axle saddle 2. The protective layer 14 is also composed of fiber-reinforced duroplastic synthetic material. The fiber-reinforced duroplastic synthetic material of the laminate 9 is covered outside the connecting elemnts 4 with an upper and a lower non-bearing cover layer 15 of a soft thermoplastic synthetic material.

The leaf spring 1 shown in FIG. 2 of the drawing is formed as a double leaf spring 10 with a main spring leaf 11 and an additional spring leaf 12 arranged under the main spring leaf 11. Each spring leaf includes a bearing laminate 9 and the protective layers 14 above the laminate and below the laminate in the region of clamping with the axle saddle, and the cover layers 15 outside the region of clamping with the axle saddle.

The bearing laminate 9 and the cover layers 15 have the same construction as in the embodiment of FIG. 1. However, the protective layers 14 are partially milled off, and the cover layers 15 in the region inside the briden, or connecting element, are removed and not filled with the fiber-reinforced material, and therefore are respectively thinner.

The embodiment of the double leaf spring 10 is used for providing a central supporting plate 13 in addition to the supporting plate 6 and the supporting plate 7. The supporting plate 13 is located between the main spring leaf 11 and the additional spring leaf 12, and can be composed for example of metal or fiber-reinforced duroplastic synthetic material. In the region outside the connecting elements, the spring leaves 11 and 12 are connected with the central supporting plate 13 via pressure cushions 8 of rubber-elastic material. The pressure cushions 8 can be pretensioned. The supporting plates 6, 7 and 13 are provided outside the connecting elements with recesses for accommodating the pressure cushions 8.

In the second embodiment, the upper supporting plate 7 is convexly shaped in the region between the connecting elements and at its upper side 7a which abuts against the clamping plate. In other words, it has a slight curvature towards the clamping plate.

The invention is not limited to the details shown since various modifications and structural changes are possible without departing in any way from the spirit of the present invention.