Composite spring design that also performs the lower control arm function for a conventional or active suspension system

The present invention relates generally to a vehicle suspension system. More specifically, the present invention relates to a composite spring and method of manufacturing such a spring that functions as a lower control arm while simultaneously serving as the coil spring, stabilizer bar and shock absorber in a suspension system. The present invention includes a flexible, resilient composite spring pivotally connected to the vehicle wheel assembly by standard means such as a ball joint and knuckle. The composite spring is formed having a sinusoidal profile with rectangular cross-section preferably spanning transversely between parallel vehicle wheel assemblies. The composite spring is pivotally connected to the parallel vehicle frames by opposing perpendicular brackets welded to an upper and lower portion of the vehicle frame. A rubber bushing is preferably provided within each bracket and is in contact with opposing sides of the composite spring, allowing the spring to pivot between the vehicle frame. The composite spring is preferably formed with carbon and glass fibers. The sinusoidal composite spring blank is preferably molded with a neutral axis extending along the length of the spring at a midpoint of the sinusoidal profile.