JP2019528408A - Method for manufacturing leaf spring and chassis for vehicle with leaf spring and motor - Google Patents

Abstract

A method of manufacturing a leaf spring from a fiber composite material capable of manufacturing at least one thick portion at a low manufacturing cost. A method for manufacturing a leaf spring (1) from a fiber composite material, wherein the leaf spring (1) is made of a plurality of fiber layers having at least one thick portion located between ends in the longitudinal direction. In the method, at least one thick portion is defined by at least one insertion member 8, each of which is pre-manufactured as a unit, followed by an upper cover layer 6 and a lower cover layer, respectively. 7 is arranged in the range of the thick portion to be defined.

Description

  The present invention relates to a method for manufacturing a leaf spring from a fiber composite material, and the leaf spring is made of a plurality of fiber layers having at least one thick portion located between ends in the longitudinal direction. The present invention further relates to a chassis for a leaf spring and a motor vehicle.

  In a chassis of a motor vehicle, a leaf spring that elastically supports the structure of the vehicle with respect to a wheel provided in a wheel support portion is used as a support spring. The essential advantage of the leaf spring is that it can function as a structural element for coupling the structure and the shaft at the same time as other spring structures and can serve as a wheel guide function. If a plurality of leaf springs are used, a certain amount of buffering can be obtained by the frictional force between the leaf springs, so that the leaf spring can assist the role of the vibration damper.

  The leaf springs are produced from the fiber composite material in the meantime, so that the above-mentioned advantages can be realized at the same time with a small weight. For this purpose, a leaf spring is usually composed of a plurality of fiber layers, and these fiber layers are positioned relative to each other in accordance with the required leaf spring configuration, and then compacted, and subsequently made into a material-bonded type by a synthetic resin matrix. Combined with each other. At this time, different characteristics of the leaf spring can be realized according to the geometric shape and material selection of the leaf spring finally formed.

  From Patent Document 1, it is clear how to manufacture a leaf spring from a fiber composite material, and the leaf spring is manufactured from a plurality of fiber layers. Here, a thick portion having a thickness larger than that of the other portions of the leaf spring is formed between the end portions of the leaf spring, and this thick portion has fiber layers having different lengths alternately. It is manufactured by extending from the end portion to a desired range, and covering it here. And the covering of this fiber layer obtained in a desired range becomes a thick part there.

German Patent Invention No. 102010050065

  Starting from the above-described prior art, an object of the present invention is to obtain a method of manufacturing a leaf spring from a fiber composite material, and at this time, it should be possible to manufacture at least one thick part at a low manufacturing cost. It is.

  This problem is solved in relation to its characteristic part on the basis of the premise part of claim 1. The dependent claims which follow each represent an advantageous development of the invention. In addition, a leaf spring according to the invention is the subject of claim 9, whereas a chassis with a leaf spring is claimed in claim 10.

  According to the present invention, in a method of manufacturing a leaf spring from a fiber composite material, the leaf spring is manufactured by a plurality of fiber layers having at least one thick portion located between ends in the longitudinal direction. Therefore, according to the present invention, the leaf spring is manufactured with a plurality of individual fiber layers forming a fiber-synthetic resin composite member in combination with a synthetic resin. Here, in the meaning of the invention, the fibers are reinforcing fibers, in particular in the form of glass fibers, surrounded by a synthetic resin matrix. At this time, the synthetic resin matrix is preferably formed of a thermosetting synthetic resin that may exist in the form of an epoxy resin.

  At this time, in the leaf spring to be manufactured, at least one thick portion is formed between the end portions during manufacture. Here, the “thick portion” can be understood as a part of a leaf spring configured with a much larger thickness than other portions of the leaf spring, that is, a larger extension in the expansion and contraction direction. At this time, it is possible to provide one or more such thickened ranges along the longitudinal extension of the leaf spring, which may be configured to correspond to each other or to differ in thickness.

  The present invention provides at least one meat by means of at least one insertion member, which is pre-manufactured as a unit and is subsequently arranged between the upper cover layer and the lower cover layer in the range of the thick part to be defined respectively. It includes a technical suggestion that the thick part is defined. Thus, in other words, in the method according to the invention, at least one insert is pre-manufactured and this pre-manufactured insert is used in the further manufacturing process of the actual leaf spring in the lower cover layer and the upper cover. It is arranged in a range to be thickened between the cover layers, and after joining with the cover layer, a desired thickened portion is defined there.

  At this time, such a configuration of the method has the advantage that it is possible to reduce the production costs by producing in advance at least one insertion member. In other words, the actual leaf spring is divided into a plurality of components, which are integrated for the first time at the end of the manufacturing process. Thereby, in the insertion member, the positioning and bonding of the individual fiber layers can be configured more simply than if the fiber layers are stacked together in the course of the final leaf spring for the fiber layers. is there. Thereby, as a further advantage, there is a pre-fabricated configuration with the possibility of various combinations of inserts with different cover layers, whereby different properties of the leaf spring can be realized, Manufacturing can be configured modularly. In addition, it is possible at this time to combine different pre-manufactured inserts with each other. Overall, one or more pre-manufactured inserts are placed at one or each location between the cover layers, thereby realizing one or more thickness ranges, Manufacturing can be simply configured.

  On the other hand, in the case of Patent Document 1, each thick portion of the leaf spring to be manufactured is configured by realizing an appropriate cover layer of the fiber layer, and each of the fiber layers is in the axial direction of the leaf spring. Alternately extending from the end to the appropriate range. This is configured to be correspondingly costly. This is because for manufacturing, the fiber layers for the fiber layers need to be laminated together and the misalignment of the individual layers should be prevented before final bonding.

  That at least one insertion member is “pre-manufactured as a unit” means, in the sense of the present invention, that the insertion member was pre-manufactured as a fiber-synthetic resin composite member during the pre-manufacturing process. To do. At this time, preferably, the individual fiber layers of the insert member are pre-compacted in the furnace process and tied together in a synthetic resin matrix.

  In principle, depending on the properties of the final leaf spring to be achieved, the insert can be made of the same fiber composite material as the cover layer or can be made of a different material. It is. Similarly, the cover layer can be composed of one or the same material or can be formed of different materials.

  In accordance with an embodiment of the present invention, at least one insertion member is pre-configured with a plurality of fiber layers, the fiber layers being joined together so as to overlap at least one part, whereby each part A greater thickness is specified. Here, in a development form of this embodiment, fiber layers having different lengths are bonded to each other. Thus, the at least one insertion member is composed of different fiber layers according to a predefined pattern, and the thickness to be achieved is realized by a cover layer with the purpose of different fiber layers.

  According to an alternative or supplementary configuration of the invention, the at least one insertion member is pre-configured with a plurality of fiber layers and at least one shorter fiber layer is at least one longer. By fixing to the fiber layer, at least one part having a greater thickness is produced. Thus, in this case, the desired thickness of the at least one insertion member is achieved by placing one or more shorter fiber layers on one or more longer fiber layers. Thus, the fibers are laminated together.

  According to another embodiment of the invention, the upper cover layer and / or the lower cover layer are each formed by a plurality of fiber layers. Therefore, according to the present invention, the upper cover layer, the lower cover layer, the upper cover layer, and the lower cover layer are each composed of a plurality of fiber layers. Thereby, depending on the selection of the number of fiber layers, it is possible to influence the characteristics of the leaf spring to be finally produced. At this time, in the meaning of the present invention, it is also conceivable to manufacture the upper cover layer or the lower cover layer in advance within the scope of the previous process. However, instead of this, it is possible to connect the individual fiber layers for the first time in a range where they are combined with at least one insertion member located in the middle.

  In the development of the above-described embodiment, the plurality of fiber layers have the same length. Particularly preferably, at this time, the fiber layer of the upper cover layer and / or the lower cover layer extends from the axial end of the final leaf spring to the other end in the longitudinal direction of the leaf spring. is doing.

  Another advantageous embodiment of the invention is that the at least one thickened portion is formed by a plurality of insertion members, each located in the middle. Accordingly, the individual thick portions are formed by the interaction of the plurality of insertion members, and at this time, these insertion members preferably correspond to each other and are mutually connected between the upper cover layer and the lower cover layer. It is arranged in mirror symmetry. Due to this interaction, it is possible to realize a much thicker wall by means of the column members configured as the same member.

  In the leaf spring manufactured using the method according to the present invention, at least one thick portion is formed between the end portions in the longitudinal direction, and at least one insertion member is provided in each range of the at least one thick portion. The insertion member is provided between the upper cover layer and the lower cover layer, and the insertion member is connected to the cover layer as a pre-manufactured unit. And such a leaf | plate spring is a part of chassis for vehicles with a motor especially, Furthermore, the leaf | plate spring used can be manufactured according to the above-mentioned aspect.

  The invention is not limited to the described combinations of the appended claims and the dependent claims. Furthermore, the individual features can be combined with one another, particularly if the individual features are derived from the claims, the following description of preferred embodiments of the invention or directly from the drawings. Reference to drawings by use of symbols in the claims does not limit the protective scope of the claims.

  Advantageous embodiments of the invention described below are illustrated in the drawings.

It is a figure which shows schematically the state in which the leaf | plate spring of this invention corresponding to the 1st Embodiment of this invention was completed. It is a figure which shows schematically the leaf | plate spring based on FIG. 1 decomposed | disassembled into the structural member. FIG. 3 is an individual view schematically showing the insertion member according to FIG. 2 before completion. It is an individual figure showing roughly an insertion member in a completed state. FIG. 3 is an individual view schematically showing the upper cover according to FIG. 2 before completion. FIG. 3 is an individual view schematically showing the upper cover according to FIG. 2 before completion. It is a figure which shows schematically the leaf | plate spring corresponding to the 2nd Embodiment of this invention before completion. It is a figure which shows schematically the leaf | plate spring corresponding to the 3rd Embodiment of this invention before completion.

  From FIG. 1, a schematic illustration of a leaf spring 1 is clear, and this leaf spring is configured corresponding to the first embodiment of the present invention. As can be seen from FIG. 1, the leaf spring 1 includes two thick portions 2, 3, and these thick portions are positioned apart from each other in the longitudinal direction between the end portions 4, 5. Here, in the range of the thick portions 2 and 3, the leaf spring 1 is configured to have a thickness that is clearly greater than the end-side portion and the central range located therebetween. At this time, FIG. 1 shows the leaf spring 1 in a completed state, and in this completed state, a plurality of fiber layers are surrounded by a synthetic resin matrix, particularly in the form of glass fibers. The fiber-synthetic resin composite member is formed. At this time, the synthetic resin is formed of a thermosetting synthetic resin, and preferably exists as an epoxy resin.

  As a feature, the leaf spring 1 is configured as an assembly kit with a plurality of pre-manufactured components, as is apparent from FIG. That is, from FIG. 2, the leaf spring 1 is formed of an upper cover layer 6, a lower cover layer 7 and a total of four insertion members 8, which have the same structure, It is arranged between the upper cover layer 6 and the lower cover layer 7. Specifically, at this time, the insertion member 8 is provided at a location between the upper cover layer 6 and the lower cover layer 7 while being positioned in mirror symmetry with respect to each other in pairs, Later, the leaf spring 1 is provided with the thick portions 2 and 3.

  The cover layers 6, 7 and the insert member 8 are each pre-manufactured from a plurality of fiber layers in a prior process step, which is illustrated in FIGS. 3 and 4 for the insert member 8, whereas in FIG. FIG. 6 shows a preliminary production of the lower cover layer 7. As for the insertion member 8, it can be seen from FIG. 3 that a plurality of fiber layers 9 to 13 having different lengths are arranged to overlap each other. Here, the fiber layers 10 and 13 are the longest so that the fiber layer 10 covers the fiber layers 11 and 12 arranged so as to overlap each other and the fiber layer 13 positioned on the uppermost side overlaps with the fiber layer 10. Arranged in the fiber layer 9. This draws the desired profile of the insert 8 and then the fiber layers 9-13 to the wedge profile illustrated in FIG. 4 in the furnace process so that they are ultimately surrounded by the synthetic resin matrix. Compacted in advance.

  On the other hand, as can be seen from FIGS. 5 and 6, the upper cover layer 6 and the lower cover layer 7 are each formed of a plurality of fiber layers 14 having the same length. At this time, each of the fiber layers 14 has a length corresponding to the length defined between the end portions 4 and 5 in the subsequent leaf spring 1. In addition, as can be seen from FIGS. 5 and 6, the upper cover layer 6 is composed of two fiber layers 14 while the lower cover layer 7 is composed of four fiber layers 14 in total. Is formed. The upper cover layer 6 and the lower cover layer 7 are similarly compacted in advance and tied together in a synthetic resin matrix. In the completion process, the final leaf spring 1 is manufactured from the upper cover layer 6, the four insertion members 8 positioned therebetween, and the lower cover layer 7.

  Further, FIG. 7 shows components of the leaf spring 15 corresponding to the second embodiment of the present invention. Unlike the above-described embodiment, the upper cover layer 16 and the lower cover layer are composed of the same number of fiber layers, here four fiber layers, so that the upper cover layer 16 and the lower cover layer are formed. 17 are configured identically. The same applies to the components of the leaf spring 18 according to FIG. 8, in which the upper cover layer 19 and the lower cover layer 20 have the same structure and therefore correspond to each other. Realized as a component. Unlike the above-described embodiment, at this time, the upper cover layer 19 and the lower cover layer 20 are each formed of two fiber layers.

  With the method according to the invention, it is possible to produce leaf springs with low production costs and at the same time it is possible to realize different thickness courses without problems.

DESCRIPTION OF SYMBOLS 1 Leaf spring 2 Thick part 3 Thick part 4 End part 5 End part 6 Upper cover layer 7 Lower cover layer 8 Insertion member 9 Fiber layer 10 Fiber layer 11 Fiber layer 12 Fiber layer 13 Fiber layer 14 Fiber layer 15 Leaf spring 16 Upper cover layer 17 Lower cover layer 18 Leaf spring 19 Upper cover layer 20 Lower cover layer

Claims (10)

A method for producing a leaf spring (1; 15; 18) from a fiber composite material, wherein the leaf spring (1; 15; 18) is located between the ends (4,5) in the longitudinal direction. Manufactured by a plurality of fiber layers (9-14) having a thick portion (2, 3),
Said at least one thick part (2, 3) is defined by at least one insertion member (8), respectively, which is pre-manufactured as a unit, followed by an upper cover layer (6; 16), respectively. 19) and the lower cover layer (7; 17; 20), the method being characterized in that it is arranged in the range of said thick part (2, 3) to be defined.   The at least one insertion member (8) is composed of a plurality of fiber layers (10-13) in advance, and the fiber layers are bonded to each other so as to cover at least one part, thereby The method according to claim 1, wherein the thickness is defined.   3. Method according to claim 2, characterized in that the fiber layers (11-13) of different lengths are bonded together.   The at least one insertion member (8) is pre-configured with a plurality of fiber layers (9-13) and at least one shorter fiber layer (10-13) is fixed to at least one longer fiber layer (9) The method of claim 1, wherein at least one portion having a greater thickness is produced.   The upper cover layer (6; 16; 19) and / or the lower cover layer (7; 17; 20) are each formed by a plurality of fiber layers (14). The method described in 1.   The plurality of fiber layers (14) of the upper cover layer (6; 16; 10) or the lower cover layer (7; 17; 20) have the same length. The method of claim 5.   The method according to claim 1, characterized in that the at least one thick part (2, 3) is formed by a plurality of insertion members (8) respectively located in the middle.   8. Method according to claim 7, characterized in that the insert members (8) corresponding to each other are arranged mirror-symmetrically with respect to each other. A leaf spring (1; 15; 18) made of a fiber composite material, wherein at least one thick portion (2, 3) is formed between end portions (4, 5) in the longitudinal direction. In
In each region of the at least one thick part (2, 3), at least one insertion member (8) has an upper cover layer (6; 16; 19) and a lower cover layer (7; 17; 20). The at least one insertion member (8) is connected to the cover layer (6, 7; 16, 17; 19, 20) as a prefabricated unit. Leaf spring.   A chassis for a motor vehicle with the leaf spring according to claim 9.

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