Molding method and mold for integral molding of composite leaf springs and metal coils

Abstract

This invention relates to the field of leaf spring manufacturing technology, specifically to a molding method for integrally molding a composite leaf spring and a metal lug, comprising: S1, blanking: Let the leaf spring thickness be h, length be L, width be b, outer diameter of the metal lug be R, and the thickness of a single layer of prepreg tape be m. The required number of prepreg tape layers is (h / m=)n layers. When cutting the prepreg tape, it is divided into an upper half and a lower half to ensure that the seam of each prepreg tape joint does not occur at the same location. The length of each prepreg tape differs by ΔL. When the blanking length of the upper half is L1, the blanking length of the lower half is L2. The blanking length is as follows: The cut lower half material is placed sequentially in the lower mold. This integral molding of the composite leaf spring and metal lug 1, with local reinforcement, avoids damage caused by opening holes in the leaf spring body, avoids stress concentration at the original bonding point between the metal lug and the leaf spring, and improves the interlayer performance of the transition area between the metal lug and the leaf spring.

Description

Technical Field

[0001] This invention relates to the field of leaf spring manufacturing technology, specifically to a molding method and mold for integrally molding a composite leaf spring and a metal coil. Background Technology

[0002] Currently, most automotive leaf springs utilize metal structures. However, with the increasing demand for lightweight structural design, traditional metal structures such as steel and aluminum alloys are no longer sufficient to meet weight reduction requirements. Fiber composite materials, due to their high specific strength and specific stiffness, as well as their designability and lightweight characteristics, are finding increasingly widespread applications in fields such as rail transportation and aerospace.

[0003] Compared to traditional metallic materials, composite materials can improve the damping properties of structures while also reducing weight. Fiber composite materials exhibit superior specific stiffness, strength, and damping properties in the fiber direction compared to metallic materials.

[0004] There are three main types of composite leaf spring lugs: bonded, bonded-wrapped, and open. The bonded type involves bonding the extended fibers of the lug to the leaf spring; the bonded-wrapped type involves wrapping the outer layer of composite material around the bonded type, but the inner fibers are not continuous; and the open type separates the lug from the leaf spring at the end.

[0005] All of the above-mentioned fiber types exhibit discontinuity. Currently, the most commonly used method is to connect metal coils with composite leaf springs. Some metal coils have beveled ends to reduce localized compressive stress on the leaf spring; others have composite leaf springs with stepped ends to shift stress concentration to the connection point at the opening; still others have metal coils fabricated as separate supporting leaf springs. However, all of these methods suffer from stress concentration and opening damage. Summary of the Invention

[0006] Therefore, the technical problem to be solved by the present invention is to overcome the problems of stress concentration and opening failure in the prior art of composite material leaf springs, thereby providing a molding method and mold for integral molding of composite material leaf springs and metal coils.

[0007] To solve the above-mentioned technical problems, the present invention provides a molding method for integral molding of composite leaf spring and metal lug, including: S1, material cutting: Let the thickness of the leaf spring be h, the length be L, the width be b, the outer diameter of the metal lug be R, the thickness of a single layer of prepreg tape be m, and the required number of prepreg tape layers be (h / m=)n layers; when cutting the prepreg tape, it is divided into an upper half and a lower half to ensure that the joint of each prepreg tape joint does not occur at the same place, and the length of each prepreg tape differs by △L. When the material cutting length of the upper half is L1, the material cutting length of the lower half is L2; ​​the material cutting length is as follows: the cut lower half material is placed in the lower mold in sequence, first the longest material, the first strip of the lower half, and last the shortest material, the n / 2 strip of the lower half; S2, laying the prepreg tape: after the lower half prepreg tape is placed in the corresponding position, the metal lug is placed in the corresponding position to prepare for the metal lug pre-embedding: during molding, the lower half is first laid in the mold. The shortest strip, the n / 2 strip, is laid out according to the shape of the lower mold and the metal lug. Then, the longest strip on the upper half, i.e., the n / 2 strip, is joined with the n / 2 strip on the lower half at the metal lug. The prepreg strips are laid out one by one in the order of the upper and lower halves until the shortest strip on the upper half is joined with the longest strip on the lower half. Each joint is staggered to avoid the same location and eliminates the risk of material shortage. S3, Reinforcement: After laying out the strips, the upper mold is pressed down, and the metal lug and composite leaf spring are formed as a whole. The cross-sectional change in the transition area between the metal lug and the leaf spring is large. When subjected to tensile and bending loads, it will lead to excessive local shear stress. After the entire prepreg strip is laid out, the two side segments in the lower mold are removed for local interlayer reinforcement. S4, Molding: The segmented blocks are connected to the lower mold through positioning holes and bolts. After heat sealing, curing, and demolding, the composite leaf spring product is completed.

[0008] Furthermore, the length of △L is: △L=2×3.14×R×2 / n.

[0009] Furthermore, the length of L2 is: L2 = 2 × L + 2 × 3.14 × R × 2 - L1.

[0010] Furthermore, the length of the first strip on the lower half is: 2×L+2×3.14×R×2-(L+△L).

[0011] Furthermore, the length of the n / 2th strip on the lower half is L + ΔL.

[0012] The present invention also provides a mold for the molding method of integrally molding composite leaf spring and metal coil, comprising: an upper mold, wherein an arc-shaped clamping member is provided in the middle of the upper mold and a first arc-shaped groove is provided at both ends of the arc-shaped clamping member; a lower mold, wherein an arc-shaped groove is provided in the lower mold and a second arc-shaped groove is provided at both ends of the arc-shaped groove, a prepreg is laid in the arc-shaped groove, and the metal coil is disposed in the first arc-shaped groove and the second arc-shaped groove; a reinforcing opening is provided on the lower mold and is disposed close to the arc-shaped groove; and a segmented block is disposed in the reinforcing opening.

[0013] Furthermore, the curvature of the arc-shaped clamping element is the same as that of the arc-shaped groove.

[0014] Furthermore, the upper mold includes: a first body, the arc-shaped clamping member being disposed on the first plate; and multiple notches, the multiple notches being disposed at the top corners of the first plate.

[0015] Furthermore, the lower mold includes: a second plate body, the second plate body being an arc-shaped plate body, the arc-shaped groove being disposed in the middle of the arc-shaped plate body and adapted to the arc-shaped clamping member, and protrusions being provided corresponding to the notches, the number of protrusions corresponding to the number of notches.

[0016] Furthermore, the reinforcing opening is a through hole provided on the lower mold.

[0017] The technical solution of this invention has the following advantages:

[0018] 1. The molding method for integral molding of composite leaf spring and metal lug provided by the present invention includes: S1, material cutting: Let the thickness of the leaf spring be h, the length be L, the width be b, the outer diameter of the metal lug be R, the thickness of a single layer of prepreg tape be m, and the required number of prepreg tape layers be (h / m=)n layers; when cutting the prepreg tape, it is divided into an upper half and a lower half to ensure that the seam of each prepreg tape joint does not occur at the same place, and the length of each prepreg tape differs by △L. When the material cutting length of the upper half is L1, the material cutting length of the lower half is L2; ​​the material cutting length is as follows: the cut lower half material is placed in the lower mold in sequence, first the longest material, the first strip of the lower half, and last the shortest material, the n / 2 strip of the lower half; S2, laying the prepreg tape: after the lower half prepreg tape is placed in the corresponding position, the metal lug is placed in the corresponding position to prepare for the metal lug pre-embedding: during molding, the shortest strip of the lower half is laid first. The n / 2 strip is laid out according to the shape of the lower mold and the metal lug. Then, the longest strip on the upper half, i.e., the n / 2 strip, is joined with the n / 2 strip on the lower half at the metal lug. The prepreg strips are laid out one by one in the order of the upper and lower halves until the shortest strip on the upper half is joined with the longest strip on the lower half. Each joint is staggered to avoid the same location and eliminates the risk of material shortage. S3, Reinforcement: After laying out, the upper mold is pressed down, and the metal lug and composite leaf spring are formed as a whole. The cross-sectional change in the transition area between the metal lug and the leaf spring is large. When subjected to tensile and bending loads, it will lead to excessive local shear stress. After the entire prepreg strip is laid out, the two sides of the lower mold are removed for local interlayer reinforcement. S4, Molding: The segmented blocks are connected to the lower mold through positioning holes and bolts. After heat sealing, curing, and demolding, the composite leaf spring product is completed.

[0019] The composite leaf spring and metal lug are integrally molded and locally reinforced, which avoids the damage caused by opening holes in the leaf spring body, avoids stress concentration at the original bonding point of the metal lug and leaf spring, improves the interlaminar performance of the transition zone 19 between the metal lug and leaf spring, improves the cycle fatigue life of the leaf spring, and reduces the possibility of failure of the composite leaf spring. This makes the composite leaf spring suitable for use in commercial vehicles, heavy trucks and other heavy-duty vehicles.

[0020] 2. The molding method for integral molding of composite leaf spring and metal coil provided by the present invention uses a mold comprising: an upper mold, wherein an arc-shaped clamping member is provided in the middle of the upper mold and a first arc-shaped groove is provided at both ends of the arc-shaped clamping member; a lower mold, wherein an arc-shaped groove is provided inside the lower mold and a second arc-shaped groove is provided at both ends of the arc-shaped groove, a prepreg tape is laid in the arc-shaped groove, and a metal coil is disposed in the first arc-shaped groove and the second arc-shaped groove; a reinforcing opening is provided on the lower mold and is disposed close to the arc-shaped groove; and a segmented block is disposed in the reinforcing opening.

[0021] By setting an arc-shaped clamping element in the middle of the upper mold and setting first arc-shaped grooves at both ends of the upper mold, the arc-shaped clamping element is adapted to the arc-shaped groove of the lower mold. The arc-shaped groove is used to place the prepreg tape. Second arc-shaped grooves are set at both ends of the arc-shaped groove of the lower mold. The first and second arc-shaped grooves form a circular structure, which is used to place the metal lug. Thus, the prepreg tape and metal lug are formed by the upper and lower molds, making the prepreg tape and metal lug a single piece, i.e., a composite leaf spring. Simultaneously, a reinforcing opening is provided on the lower mold. By placing the segmented block inside the reinforcing opening, the transition area between the metal lug and the leaf spring is reinforced, preventing large changes in the cross-section of the transition area from causing excessive local shear stress under tensile and bending loads.

[0022] The molding method for integrally molding the composite leaf spring and metal lugs utilizes a mold that effectively avoids excessive local shear stress and prevents damage to the openings on the leaf spring, thus effectively improving the stiffness and overall strength of the leaf spring.

[0023] 3. In the molding method for integrally molding composite leaf springs and metal coils provided by this invention, the curvature of the arc-shaped clamping component and the arc-shaped groove are the same. That is, the arc-shaped clamping component and the arc-shaped groove are perfectly matched, ensuring the overall consistency of the leaf spring supported by the molding mold.

[0024] 4. The molding method for integrally molding composite leaf springs and metal coils provided by this invention utilizes a mold in which the segmented block includes a segmenting plate and a fixing block, wherein the segmenting plate and the fixing block are integrally molded parts. Manufacturing the segmenting plate and the fixing block as an integral molded part effectively ensures the overall strength and rigidity of the segmented block, and guarantees the reinforcing capability of the segmented block.

[0025] The summary section is provided to present the chosen concepts in a simplified form, which will be further described in the detailed description below. The summary section is not intended to identify essential or indispensable features of this disclosure, nor is it intended to limit the scope of this disclosure. Attached Figure Description

[0026] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0027] Figure 1 A schematic diagram of the leaf spring structure provided by the molding method for integral molding of composite material leaf spring and metal lug provided by the present invention;

[0028] Figure 2 A schematic diagram of the cutting length of the prepreg in the molding method for integral molding of composite leaf springs and metal lugs provided by the present invention;

[0029] Figure 3 A diagram showing the cutting length of the prepreg used in the molding method for integral molding of composite leaf springs and metal lugs provided by the present invention;

[0030] Figure 4 A schematic diagram of the lower half of the prepreg tape being placed in the lower mold in the molding method for integral molding of composite leaf springs and metal coils provided by the present invention;

[0031] Figure 5 A schematic diagram of the metal coil pre-embedding in the molding method for integral molding of composite leaf spring and metal coil provided by the present invention;

[0032] Figure 6 A schematic diagram of the laying and joining of the second prepreg tape on the lower half of the molding method for integral molding of composite leaf spring and metal lug provided by the present invention;

[0033] Figure 7 A schematic diagram showing the prepreg tape laid out in the molding method for integral molding of composite leaf springs and metal lugs provided by the present invention;

[0034] Figure 8 A schematic diagram of the transition area between the leaf spring and the metal lug in the molding method for integral molding of composite leaf spring and metal lug provided by the present invention.

[0035] Figure 9 A schematic diagram of partial reinforcement of the composite leaf spring in the molding method of integral molding of composite leaf spring and metal lug provided by the present invention.

[0036] Figure 10 A schematic diagram of the mold used in the molding method for integral molding of composite leaf springs and metal coils provided by the present invention;

[0037] Figure 11 A schematic diagram of the upper mold structure used in the molding method for integral molding of composite leaf springs and metal coils provided by the present invention;

[0038] Figure 12 A perspective view of the upper mold used in the molding method for integral molding of composite leaf spring and metal coil lug provided by the present invention;

[0039] Figure 13 A schematic diagram of the lower mold used in the molding method for integral molding of composite leaf springs and metal coils provided by the present invention;

[0040] Figure 14A top view of the lower mold used in the molding method for integral molding of composite leaf spring and metal lug provided by the present invention;

[0041] Figure 15 A bottom view of the lower mold used in the molding method for integral molding of composite leaf spring and metal lug provided by the present invention;

[0042] Figure 16 A schematic diagram of the segmented block structure of the mold used in the molding method for integral molding of composite leaf springs and metal coils provided by the present invention;

[0043] Explanation of reference numerals in the attached figures:

[0044] 1. Metal coiled ear; 2. Leaf spring; 3. Butt joint; 4. Upper mold; 5. Arc-shaped clamping component; 6. First arc-shaped groove; 7. Lower mold; 8. Arc-shaped groove; 9. Second arc-shaped groove; 10. Reinforcing opening; 11. Split block; 12. First body; 13. Notch; 14. Second plate; 15. Protrusion; 16. Split plate; 17. Fixing block; 18. Locking hole; 19. Transition area. Detailed Implementation

[0045] In the following description, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments can be modified in various ways without departing from the spirit or scope of this disclosure. Therefore, the drawings and description are to be considered exemplary in nature and not restrictive.

[0046] In the description of this disclosure, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing this disclosure and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this disclosure. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the stated features. In the description of this disclosure, "a plurality of" means two or more, unless otherwise explicitly specified.

[0047] In the description of this disclosure, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "joint" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections, electrical connections, or connections that allow for communication; they can refer to direct connections or indirect connections through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this disclosure according to the specific circumstances.

[0048] In this disclosure, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0049] The following disclosure provides numerous different embodiments or examples for implementing various structures of this disclosure. To simplify the disclosure, specific examples of components and arrangements are described below. These are merely examples and are not intended to limit the scope of this disclosure. Furthermore, reference numerals and / or letters may be repeated in different examples; such repetition is for simplification and clarity and does not in itself indicate a relationship between the various embodiments and / or arrangements discussed. In addition, various specific examples of processes and materials are provided in this disclosure, but those skilled in the art will recognize the application of other processes and / or the use of other materials.

[0050] The preferred embodiments of this disclosure are described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit this disclosure.

[0051] Please see Figures 1 to 16As shown, this invention provides a molding method for integrally molding a composite leaf spring and a metal lug, including: S1, material cutting: Let the thickness of the leaf spring 2 be h, the length be L, the width be b, the outer diameter of the metal lug 1 be R, the thickness of a single layer of prepreg tape be m, and the required number of prepreg tape layers be (h / m=)n layers; when cutting the prepreg tape, it is divided into an upper half and a lower half to ensure that the seam of each prepreg tape joint does not occur at the same place, and the length of each prepreg tape differs by △L. When the material cutting length of the upper half is L1, the material cutting length of the lower half is L2; ​​the material cutting length is as follows: the cut lower half material is placed in the lower mold 7 in sequence, first the longest material, the first strip of the lower half, and finally the shortest material, the n / 2 strip of the lower half; S2, laying the prepreg tape: after the lower half prepreg tape is placed in the corresponding position, the metal lug 1 is placed in the corresponding position to prepare for the pre-embedding of the metal lug 1: during molding, first the shortest strip of the lower half, the n / 2 strip, is laid in the corresponding position. Two strips are laid out according to the shape of the lower mold 7 and the metal lug 1. Then, the longest strip on the upper half, i.e., the n / 2 strip, is joined with the n / 2 strip on the lower half at the metal lug 1. The prepreg strips are laid out one by one in the order of the upper half and the lower half until the shortest strip on the upper half is joined with the longest strip on the lower half. Each joint is staggered so that it does not occur in the same place and there is no risk of material shortage. S3, Reinforcement: After the laying is completed, the upper mold 4 is pressed, and the metal lug 1 and the composite leaf spring 2 are integrally formed. The cross-section of the transition area 19 between the metal lug 1 and the leaf spring 2 changes greatly. When subjected to tensile and bending loads, it will cause excessive local shear stress. After the overall prepreg strip is laid out, the two sides of the lower mold 7 are removed for local interlayer reinforcement. S4, Forming: The segment block 11 is connected to the lower mold 7 through positioning holes and bolts. After the product is heat-sealed, cured and demolded, the composite leaf spring 2 product is completed.

[0052] The composite leaf spring 2 and the metal lug 1 are integrally molded and locally reinforced, which avoids the damage caused by opening holes in the leaf spring 2 body, avoids stress concentration at the original bonding point of the metal lug 1 and the leaf spring 2, improves the interlaminar performance of the transition area 19 between the metal lug 1 and the leaf spring 2, improves the cycle fatigue life of the leaf spring 2, and reduces the possibility of failure of the composite leaf spring 2, so that the composite leaf spring 2 can be used in commercial vehicles, heavy trucks and other vehicles with large loads.

[0053] In some optional embodiments, the length of △L is: △L=2×3.14×R×2 / n; the length of L2 is: L2=2×L+2×3.14×R×2-L1; the length of the first strip on the lower half is: 2×L+2×3.14×R×2-(L+△L); the length of the n / 2 strip on the lower half is L+△L.

[0054] The present invention also provides a mold for a molding method for integrally molding composite leaf springs and metal coils, comprising: an upper mold 4, wherein an arc-shaped clamping member 5 is provided in the middle of the upper mold 4, and a first arc-shaped groove 6 is provided at both ends of the arc-shaped clamping member 5; a lower mold 7, wherein an arc-shaped groove 8 is provided inside the lower mold 7, and a second arc-shaped groove 9 is provided at both ends of the arc-shaped groove 8, a prepreg tape is laid in the arc-shaped groove 8, and a metal coil 1 is disposed in the first arc-shaped groove 6 and the second arc-shaped groove 9; a reinforcing opening 10 is provided on the lower mold 7 and is disposed close to the arc-shaped groove; and a segmented block 11 is disposed in the reinforcing opening 10.

[0055] By setting an arc-shaped clamping member 5 in the middle of the upper mold 4 and setting first arc-shaped grooves 6 at both ends of the upper mold 4, the arc-shaped clamping member 5 is adapted to the arc-shaped groove 8 of the lower mold 7. The arc-shaped groove 8 is used to place the prepreg tape. A second arc-shaped groove 9 is set at both ends of the arc-shaped groove 8 of the lower mold 7. The first arc-shaped groove 6 and the second arc-shaped groove 9 form a circular structure. This circular structure is used to place the metal lug 1. Thus, the prepreg tape and the metal lug 1 are formed by the upper mold 4 and the lower mold, so that the prepreg tape and the metal lug 1 are integrated into a single piece, namely the composite material leaf spring 2. At the same time, a reinforcing opening 10 is provided on the lower mold 7. By placing the segmented block 11 in the reinforcing opening 10, the transition area 19 between the metal lug 1 and the leaf spring 2 is reinforced. This avoids a large change in the cross-section of the transition area 19 between the metal lug 1 and the leaf spring 2, which would lead to excessive local shear stress when subjected to tensile and bending loads.

[0056] The molding method for integrally molding the composite leaf spring and metal lugs utilizes a mold that effectively avoids excessive local shear stress and prevents damage to the opening on the leaf spring 2, thus effectively improving the stiffness and overall strength of the leaf spring 2.

[0057] In some optional embodiments, the arc-shaped clamping member 5 has the same curvature as the arc-shaped groove 8. That is, the arc-shaped clamping member 5 and the arc-shaped groove 8 are perfectly matched, ensuring the overall consistency of the leaf spring 2 supported by the molding die.

[0058] In some optional embodiments, the upper mold 4 includes a first body 12 and a notch 13; wherein the arc-shaped clamping member 5 is disposed on the first plate; there are multiple notches 13, and the multiple notches 13 are disposed at the top corners of the first plate.

[0059] Multiple notches 13 are provided on the first plate, and the multiple notches 13 are located at the top corners of the first plate. In this embodiment, the number of notches 13 is four.

[0060] In some optional embodiments, the lower mold 7 includes a second plate 14 and a protrusion 15; wherein the second plate 14 is an arc-shaped plate, the arc-shaped groove is provided in the middle of the arc-shaped plate and is adapted to the arc-shaped clamping member 5, the protrusion 15 is provided corresponding to the notch 13, and the number of protrusions 15 corresponds to the number of notches 13.

[0061] By setting multiple protrusions 15 on the second plate 14, and the number of protrusions 15 corresponding to the number of protrusions 14 (i.e., there are four protrusions 15), each located at the top corner of the second plate 14. In actual use, the protrusions 15 on the second plate 14 are inserted into the notches 13 of the second plate 14, thereby achieving the connection between the first plate and the second plate 14. At the same time, due to the setting of the notches 13 and the protrusions 15, relative movement between the first plate and the second plate 14 is avoided, ensuring the stability of the connection between the upper mold 4 and the lower mold 7.

[0062] In this embodiment, the reinforcing opening 10 is a through hole provided on the lower mold 7.

[0063] In some optional embodiments, the segmented block 11 includes a segmented plate 16 and a fixing block 17, wherein the segmented plate 16 and the fixing block 17 are integrally formed. Making the segmented plate 16 and the fixing block 17 into an integral form effectively ensures the overall strength and rigidity of the segmented block 11, and guarantees the reinforcing capability of the segmented block 11.

[0064] In some alternative embodiments, the cross-section of the segmented plate 16 is larger than the cross-section of the fixing block 17, which is inserted into the reinforcing opening 10. The fixing block 17 is inserted into the reinforcing opening 10, and the segmented plate 16 is disposed on the lower mold 7.

[0065] In some alternative embodiments, the molding method for integrally molding composite leaf springs and metal lugs uses a mold that further includes a locking structure for connecting the upper mold 4 and the lower mold 7, as well as the segment block 11 and the lower mold 7.

[0066] Specifically, the locking structure includes a locking hole 18, a first locking member (not shown in the figure), and a second locking member (not shown in the figure); wherein, the locking hole 18 is provided on the upper mold 4, the lower mold 7, and the segmented block 11; the first locking member passes through the upper mold 4 and the lower mold 7, locking the upper mold 4 and the lower mold 7; the second locking member is provided in the lower mold 7 and the segmented block 11.

[0067] The first locking element connects the upper mold 4 and the lower mold 7; the second locking element connects the lower mold 7 and the segmented block 11.

[0068] Multiple locking holes 18 are provided along the outer contour of the upper mold 4 and the lower mold 7, as well as near the reinforcing opening 10 of the lower mold 7. Therefore, the number of the first locking member, the second locking member, and the locking holes are matched.

[0069] In this embodiment, the first locking member and the second locking member are bolts.

[0070] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.

Claims

1. A molding method for integrally molding a composite leaf spring and a metal lug, characterized in that, include: S1, material preparation: Assume the thickness of the leaf spring (2) is h, the length is L, the width is b, the outer diameter of the metal lug (1) is R, the thickness of a single layer of prepreg tape is m, and the required number of prepreg tape layers is (h / m=)n layers; When cutting the prepreg tape, it is divided into the upper half and the lower half to ensure that the seam of the prepreg tape does not occur at the same place each time. The length of the prepreg tape differs by △L each time, △L=2×3.14×R×2 / n; When the upper half of the material is L1, the lower half of the material is L2. The cutting lengths are as follows: Place the cut lower half of the material into the lower mold (7) in sequence. First, place the longest material, the first piece of the lower half, and finally place the shortest material, the n / 2th piece of the lower half. S2, Laying the prepreg tape: After the lower half of the prepreg tape is placed in the corresponding position, the metal lug (1) is placed in the corresponding position to prepare for the pre-embedding of the metal lug (1): During molding, first lay out the shortest strip on the lower half, the n / 2th strip, according to the shape of the lower mold (7) and the metal lug (1). Then, connect the longest strip on the upper half, the n / 2th strip, with the n / 2th strip on the lower half at the metal lug (1): Following the order of the upper and lower prepreg strips, lay them one by one until the shortest strip on the upper side and the longest strip on the lower side are joined together. Each joint is staggered so that it does not occur in the same place and there is no risk of material shortage. S3, reinforcement: After the laying is completed, press the upper mold (4) to form the metal ear (1) and the composite leaf spring (2) as a whole. The cross-sectional change in the transition area (19) between the metal ear (1) and the leaf spring (2) is large. When subjected to tensile and bending loads, it will cause excessive local shear stress. After the overall prepreg tape is laid, remove the two sides of the lower mold (7) and carry out local interlayer reinforcement. S4, Molding: The segmented block (11) is connected to the lower mold (7) through positioning holes and bolts. After product heat sealing, curing and demolding, the composite material leaf spring (2) product is completed.

2. The molding method for integrally molding the composite material leaf spring and metal lug according to claim 1, characterized in that, The length of L2 is: L2 = 2 × L + 2 × 3.14 × R × 2 - L1.

3. The molding method for integrally molding the composite leaf spring and metal lug according to any one of claims 1-2, characterized in that, The length of the first strip on the lower half is: 2×L+2×3.14×R×2-(L+△L).

4. The molding method for integrally molding the composite material leaf spring and metal lug according to claim 2, characterized in that, The length of the n / 2th strip on the lower half is L + △L.

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