Leaf spring, manufacturing process and mould of that leaf spring

A process of manufacturing a leaf spring having at least one leaf of composite material including a central body having two longitudinal end zones and at least one sheet of composite material and two eyes located in the longitudinal end zones of the central body that comprise a hole for the connection of the leaf spring to a vehicle, wherein the hole comprises a longitudinal axis perpendicular to the longitudinal direction of the central body, the process comprising:

• cutting a set of fibre fabrics configured to form at least the composite material sheet of the central body,
• stacking of at least the set of fibre fabrics in a forming tool so that they are located in a longitudinal direction to the central body and stacked in a direction perpendicular to the length of said central body and so that the central body comprises the longitudinal end zones with a section transversal to the longitudinal direction of the central body increasing toward the longitudinal end of the central body,
• preforming the set of fibre fabrics for the generation of a central body preform,
• positioning the central body preform in an injection mould to proceed to the injection of polymeric matrix,
• injecting polymeric resin into the injection mould,
• curing the central body,
• cutting fibre fabrics of the eyes wherein part of the fibre fabrics comprises a cavity for embedding the longitudinal end zones of the central body and so that the cavity comprises a section transversal to the longitudinal direction of the central body increasing toward the longitudinal end of the central body,
• positioning at least the fibre fabrics of the eyes in a mould for forming the eyes in accordance with the following steps:
• positioning a set of fibre fabrics located adjacent to the external part of the eye in the eye mould, and
• positioning a set of fibre fabrics that comprise the cavity for embedding the longitudinal end zones of the central body and so that the cavity comprises a section transverse to the longitudinal direction of the central body increasing toward the longitudinal end of the central body,
• positioning the longitudinal end zones of the central body in the forming mould of the eyes so that the longitudinal end zones of the central body are embedded in the cavity of the fibre fabrics and so that the orientation of the fibre fabrics of the eyes are located in the longitudinal direction of the central body and stacked in a parallel direction to the axis of the hole, and
• moulding the eyes of the leaf spring on the longitudinal end zones of the central body.

A mould for the manufacture of a leaf spring, wherein the leaf spring includes at least one leaf of composite material that includes a central body which has two longitudinal end zones and at least one sheet made of composite material and two eyes located in the longitudinal end zones of the central body that includes a hole for the connection of the leaf spring to a vehicle, wherein the hole includes a longitudinal axis perpendicular to the longitudinal direction of the central body, the mould comprising:

• a mould cavity having the shape of the eyes for positioning fibre fabrics of the eyes and the ends of the central body of the leaf spring, wherein part of the fibre fabrics comprises a cavity for embedding the longitudinal end zones of the central body and so that the cavity comprises a section transversal to the longitudinal direction of the central body increasing toward the longitudinal end of the central body,
• the cavity for embedding the longitudinal end zones of the central body for positioning and attaching the longitudinal end zone of the central body when cured, such that the longitudinal end zones of the central body are embedded in the cavity of the fibre fabrics and so that the orientation of the fibres of the fibre fabrics of the eyes are located in the longitudinal direction of the central body and stacked in a direction parallel to the axis of the hole, and
• a pin for moulding the hole of the eye.