Gas spring and damper assembly and suspension system including the same

Abstract

An end member assembly (EM1) having a longitudinal axis (AX) is sized for fixing to a flexible spring member (300). The end member assembly (EM1) includes a first end member (400; 500) having a first surface portion (406; 522) and a plurality of protrusions (408) arranged in a circumferentially spaced relationship with each other around the longitudinal axis (AX). The second end member (400; 500) includes a plurality of grooves (506) sized to receive one of the protrusions (408). A gas spring and damper assembly (AS1) includes a damper assembly (DP1) and a gas spring assembly (GS1), the gas spring assembly including an end member assembly (EM1) and an end member assembly (600) having a flexible spring member (300) fixed between the end member assemblies (EM1; 600). Also included is a suspension system 100 including one or more gas spring and damper assemblies (AS1).

Description

Background Art

[0001] The subject matter of the present disclosure relates broadly to the field of gas spring devices, and more particularly to end member assemblies for gas spring and damper assemblies having two or more components assembled in a rotationally fixed relationship to one another. Also included are gas spring and damper assemblies including one or more such end members, and suspension systems including one or more such gas spring and damper assemblies.

[0002] The subject matter of the present disclosure may be specifically applied and used in conjunction with wheeled vehicles, and will be shown and described herein with reference thereto. However, it should be understood that the subject matter of the present disclosure may also be used in other applications and environments, and the specific uses shown and described herein are merely exemplary. For example, the subject matter of the present disclosure may be used in conjunction with gas spring and damper assemblies for non-wheeled vehicles, support structures, height adjustment systems, and actuators associated with industrial machinery, its components, and / or other such equipment. Therefore, the subject matter of the present disclosure is not intended to be limited to uses associated with suspension systems for wheeled vehicles.

[0003] Most types and kinds of wheeled motor vehicles include a sprung mass (such as, for example, a body or chassis) and an unsprung mass (such as, for example, two or more axles or other wheel engaging members between which a suspension system is disposed). Typically, the suspension system will include a plurality of spring elements and a plurality of damping devices which together enable the sprung and unsprung masses of the vehicle to move relative to each other in a somewhat controlled manner. Movement of the sprung and unsprung masses toward each other is generally referred to in the art as pitch motion, while movement of the sprung and unsprung masses away from each other is generally referred to in the art as rebound motion.

[0004] Typically, a plurality of resilient elements are used to accommodate forces and loads associated with the operation and use of the vehicle. A plurality of damping devices are operable to dissipate energy associated with undesired input and movement of the sprung mass, such as, for example, road surface input that occurs under dynamic operation of the vehicle. Typically, such dampers are liquid filled and are operatively connected between a sprung mass and an unsprung mass, such as, for example, the body and axle of the vehicle. An example of such a damping component is a conventional shock absorber commonly used in vehicle suspension systems.

[0005] Suspension systems of various types and kinds are generally well known and allow for relative movement between the sprung and unsprung masses of a vehicle. In some cases, such relative movement can impart relative rotation to the opposing end members of the gas springs of the suspension system. Such conditions often occur in gas spring and damper assemblies in which a pressurized gas spring is assembled outwardly along with an otherwise conventional damper. Such relative rotation is generally considered undesirable because such relative rotation can induce torsion in the flexible walls of the gas spring assembly, which can result in performance degradation and / or other problems.

[0006] Various designs have been developed in an effort to eliminate or otherwise address such rotation-induced torsion of the gas spring assembly. As an example, the upper end member of the gas spring can be secured to the sprung mass of the vehicle in a manner that permits rotation rather than by rigidly securing the upper end member to the unsprung mass of the vehicle. As another example, the lower end member of the gas spring can be rotatably supported on the housing of the damper, such as, for example, by using a friction-reducing bearing. However, in known designs, the configuration of the support elements that support the lower end member on the damper housing and the corresponding sealing arrangements can, in some cases, allow for undesirable lateral movement of the second end member relative to the damper housing. Attempts to minimize or at least reduce the magnitude and / or impact of such lateral movement have resulted in end member constructions having reduced manufacturability, increased assembly time and / or cost, and / or other disadvantages.

[0007] Although known structures are generally successful, the foregoing and / or other disadvantages may still exist, which may limit the wider adoption and / or use of gas spring and damper assemblies associated with vehicles and / or other applications. Therefore, it is believed to be desirable to develop structures that can help overcome the foregoing and / or other problems and / or disadvantages of known designs, and / or otherwise advance the field of vehicle suspension systems and / or components thereof. Summary of the invention

[0008] An example of an end member assembly according to the subject matter of the present disclosure can have a longitudinal axis and can be sized to be fixed to an associated flexible spring member. The end member assembly can include a first end member having a first surface portion and a plurality of protrusions arranged in a circumferentially spaced relationship with each other around the longitudinal axis. The plurality of protrusions can extend beyond the first surface portion to the end surface portion. The second end member can include a second surface portion. The second end member can be engaged with the first end member so that the second surface portion of the second end member is axially coextensive with the first surface portion of the first end member, and so that the end surface portion of the plurality of protrusions is in abutting engagement with the second surface of the second end member.

[0009] In some cases, the first end member of the end member assembly according to the preceding paragraph can include a first end member wall. In this case, the first surface portion can be a first inner surface portion extending along the first end member wall, and the plurality of protrusions extend inwardly from the first inner surface portion.

[0010] In some cases, the second end member of the end member assembly according to either of the preceding two paragraphs may include a second end member wall. In this case, the second surface portion may be a second outer surface portion extending along the second end member wall, wherein the second outer surface portion has an end surface portion oriented transversely to the second outer surface portion. The end surface portion may be sized to operatively engage an associated damper assembly.

[0011] An example of a gas spring and damper assembly according to the subject matter of the present disclosure may include a damper assembly having a longitudinally extending axis and a gas spring assembly disposed in an axially coextensive relationship with at least a portion of the damper assembly. The damper assembly may include a damper housing having a housing wall extending axially between opposite first and second ends. The housing wall may at least partially define a damping chamber containing a certain amount of damping fluid. The damper rod assembly may include an elongated damper rod and a damper piston fixed along the elongated damper rod. The damper rod assembly may be operatively engaged with the damper housing for reciprocating displacement relative to the damper housing, wherein the damper piston is disposed in the damping chamber and at least a portion of the elongated damper rod protrudes axially outward from the first end of the damper housing. The gas spring assembly may include a flexible spring member extending circumferentially around the longitudinal axis and extending longitudinally between the opposite first and second ends, so that the spring chamber is at least partially defined therebetween. The first end member assembly according to any of the three preceding paragraphs may be operably connected to the elongated damper rod and operably fixed to the first end of the flexible spring member so as to form a substantially fluid-tight connection therebetween. The second end member assembly may be supported on the damper housing and operably fixed to the second end of the flexible spring member so as to form a substantially fluid-tight connection therebetween.

[0012] An example of a suspension system according to the subject matter of the present disclosure may include a compressed gas system including a compressed gas source and a control device. The suspension system may also include at least one gas spring and damper assembly according to the preceding paragraph. The at least one gas spring and damper assembly may be placed in fluid communication with the compressed gas source via the control device so that compressed gas can be selectively transmitted into and out of the spring chamber. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 is a schematic diagram of one example of a suspension system for an associated vehicle including one or more gas spring and damper assemblies in accordance with the disclosed subject matter.

[0014] Figure 2 is a top perspective view of one example of a gas spring and damper assembly in accordance with the disclosed subject matter.

[0015] Figure 3 yes Figure 2 Side elevation view of the gas spring and damper assembly in FIG.

[0016] Figure 4 yes Figure 2 and Figure 3 Front elevation view of the gas spring and damper assembly.

[0017] Figure 5 yes Figures 2 to 4 Top plan view of the gas spring and damper assembly.

[0018] Figure 6 It is along Figure 4 The line 6-6 in Figures 2 to 5 Cross-sectional plan view of the gas spring and damper assembly.

[0019] Figure 7 It is along Figure 5 The line 7-7 in Figures 2 to 6 Cross-sectional side view of the gas spring and damper assembly.

[0020] Figure 8 yes Figures 2 to 7 Gas spring and damper components in Figure 6 An enlarged view of the portion marked as detail 8.

[0021] Fig. 9 yes Figures 2 to 8 Gas spring and damper components in Figure 7 An enlarged view of the portion marked as detail 9.

[0022] Fig.10 is an exploded view of an end member assembly according to the disclosed subject matter, such as for example Figures 2 to 9 End member assembly shown.

[0023] Fig.11 is a top perspective view of an end member according to the disclosed subject matter, such as for example Figures 2 to 10 End member shown.

[0024] Fig.12 yes Figures 2 to 11 Bottom perspective view of the end member in FIG.

[0025] Fig.13 yes Figures 2 to 12 Top plan view of the end member in.

[0026] Fig.14yes Figures 2 to 13 Side elevation view of the end member in FIG.

[0027] Fig.15 is an exploded view of another end member according to the subject matter of the present disclosure, such as for example Figures 2 to 10 End member shown.

[0028] Fig.16 yes Figures 2 to 10 as well as Fig.15 Bottom perspective view of the end member in FIG.

[0029] Fig.17 yes Figures 2 to 10 , Fig.15 as well as Fig.16 Top plan view of the end member in.

[0030] Fig.18 yes Figures 2 to 10 as well as Figures 15 to 17 Side elevation view of the end member in FIG. DETAILED DESCRIPTION

[0031] Turning now to the drawings, it should be understood that the illustrations are examples for illustrating the subject matter of the present disclosure, and such examples are not intended to be limiting. In addition, it should be understood that the drawings are not drawn to scale, and parts of specific features and / or elements may be exaggerated for the purpose of clarity and / or ease of understanding.

[0032] Figure 1 An example of a suspension system 100 operatively disposed between a sprung mass (such as, for example, an associated vehicle body BDY) and an unsprung mass (such as, for example, an associated wheel WHL or an associated suspension component SCP of an associated vehicle VHC) is shown. It should be understood that any one or more components of the suspension system may be operatively connected between the sprung mass and the unsprung mass of an associated vehicle in any suitable manner.

[0033] For example, in the illustrated arrangement, the suspension system 100 may include a plurality of gas spring and damper assemblies 102 operatively connected between a sprung mass and an unsprung mass of a vehicle. The suspension system may include any suitable number of gas spring and damper assemblies depending on desired performance characteristics and / or other factors. Figure 1 In the illustrated arrangement, the suspension system 100 includes four gas spring and damper assemblies 102, with one gas spring and damper assembly being disposed toward each corner of the associated vehicle adjacent to a corresponding wheel WHL. It should be appreciated that any other suitable number of gas spring and damper assemblies may alternatively be used in any other configuration and / or arrangement. Figure 1As shown, the gas spring and damper assembly 102 is supported between the suspension component SCP and the body BDY of the associated vehicle VHC, and includes a gas spring (or gas spring assembly) 104 and a damper (or damper assembly) 106. It should be appreciated that the gas spring 104 shown and described herein has a rolling cam type structure. However, it should be understood that other types, kinds and / or structures of gas spring assemblies may be used interchangeably without departing from the subject matter of the present disclosure.

[0034] The suspension system 100 also includes a compressed gas system 108 operatively associated with the gas spring and damper assembly for selectively providing compressed gas (e.g., air) thereto and selectively transferring compressed gas therefrom. Figure 1 In the exemplary arrangement shown in , the compressed gas system 108 includes a compressed gas source, such as a compressor 110, for example, for producing compressed air or other gases. A control device such as a valve assembly 112 is shown as being in communication with the compressor 110 and can be of any suitable construction or arrangement. In the exemplary embodiment shown, the valve assembly 112 includes a valve block 114 having a plurality of valves 116 supported thereon. The valve assembly 112 may also optionally include a suitable exhaust device, such as a muffler 118, for example, for exhausting compressed gas from the system. Optionally, the compressed gas system 108 may also include a reservoir 120, which is in fluid communication with the compressor and / or the valve assembly 112 and is suitable for storing compressed gas for a long time (e.g., seconds, minutes, hours, weeks, days, months).

[0035] The valve assembly 112 communicates with the gas springs 104 and / or dampers 106 of the assembly 102 via suitable gas delivery lines 122. In this manner, compressed gas can be selectively delivered into and / or out of the gas springs and / or dampers via the valve assembly 112 by selectively operating the valve 116, thereby changing or maintaining the height of the vehicle, for example, at one or more corners of the vehicle.

[0036] The suspension system 100 may also include a control system 124 that can communicate with any one or more systems and / or components of the vehicle VHC and / or suspension system 100, such as for selectively operating and / or controlling these systems and / or components. The control system 124 may include a controller or electronic control unit (ECU) 126 that is communicatively coupled to the compressor 110 and / or the valve assembly 112, such as, for example, via conductors or leads 128, for selectively operating and controlling the compressor and / or the valve assembly, which selective operation and / or control may include providing compressed gas to the gas spring and damper assembly 102 and exhausting compressed gas from the gas spring and damper assembly. The controller 126 may be of any suitable type, kind, and / or configuration.

[0037] The control system 124 may also optionally include one or more sensing devices 130, such as, for example, operatively associated with the gas spring and damper assembly and capable of outputting or otherwise generating data, signals, and / or other communications related to one or more of: the height of the gas spring and damper assembly; the distance between other components of the vehicle; the pressure or temperature associated with the gas spring and damper assembly and / or the wheel or tire or other components associated with the gas spring and damper assembly; and / or acceleration, load, or other input acting on the gas spring and damper assembly. The sensing device 130 may be in communication with the ECU 126, and the ECU may receive data, signals, and / or other communications from the sensing device. The sensing device may be in communication with the ECU 126 in any suitable manner, such as, for example, via conductors or leads 132. In addition, it should be understood that the sensing device may be of any suitable type, kind, and / or structure, and may operate using any suitable combination of one or more operating principles and / or techniques.

[0038] Having described an example of a suspension system (e.g., suspension system 100) that may include a gas spring and damper assembly according to the presently disclosed subject matter, the present invention will now be described in conjunction with a Figures 2 to 10 An example of such a gas spring and damper assembly is described. As shown therein, a gas spring and damper assembly AS1 (such as may be suitable for use as Figure 1 One or more of the gas spring and damper assemblies 102 in FIG. 1 are shown to include components such as may correspond to, for example, Figure 1 A gas spring (or gas spring assembly) GS1 in the gas spring 104 and such as may correspond to, for example, Figure 1 The gas spring assembly GS1 and the damper assembly DP1 may be disposed in a coextensive arrangement with each other and may be operatively secured to each other in any suitable manner, such as, for example, as described below. Figure 7 As shown, a longitudinal axis AX extends longitudinally along the assembly AS1.

[0039] The damper assembly DP1 may include a damper housing 200 and a damper rod assembly 202 at least partially received in the damper housing. The damper housing 200 extends axially between housing ends 204 and 206 and includes a housing wall 208 that at least partially defines a damping chamber 210. The damper rod assembly 202 extends longitudinally between opposite ends 212 and 214 and includes an elongated damper rod 216 and a damper piston 218 disposed along the end 214 of the damper rod assembly 202. The damper piston 218 is received in the damping chamber 210 of the damper housing 200 for reciprocating movement along the housing wall in a conventional manner. A certain amount of damping fluid 220 may be disposed in the damping chamber 210, and the damper piston 218 may be displaced through the damping fluid to dissipate kinetic energy acting on the gas spring and damper assembly AS1. Although the damper assembly DP1 is shown and described herein as having a conventional structure in which a hydraulic fluid is contained within at least a portion of the damping chamber 210, it should be recognized and understood that other types, kinds and / or structures of dampers, such as compressed gas or "air" dampers, may be used without departing from the subject matter of the present disclosure.

[0040] That is, it should be understood that in some cases, the gas spring and damper assembly according to the subject matter of the present disclosure may include dampers of other conventional structures that utilize hydraulic oil or other liquids as the damper working medium. In other cases, the damper may be of a type and kind that utilizes compressed gas as the working medium. In such cases, such gas dampers may include one or more elongated gas damping channels through which compressed gas may flow to generate compressed gas damping to dissipate kinetic energy acting on the gas spring and damper assembly. It should be understood that such one or more elongated gas damping channels may be of any suitable size, shape, configuration and / or arrangement. In addition, it should be understood that any number of one or more features and / or components may be used alone or in combination with each other to form or otherwise construct such one or more elongated gas damping channels.

[0041] The housing wall 208 may define an opening (not numbered) along the housing end 204. The damper end wall 222 may extend through the opening and may be fixed to or along the housing wall 218 so that a substantially fluid-tight connection is formed therebetween. The damper end wall 222 may include an opening (not numbered) and the elongated damper rod 216 may extend axially outward from the damping chamber 210 through the opening in a direction opposite to the housing end 206. In addition, the damper end wall (not numbered) may straddle the end 206 of the damper housing 200 so that a substantially fluid-tight connection is formed therebetween. In some cases, an end cap 224 (sometimes referred to in the art as a strike cap) including an outer side surface portion 226 may be supported on or along the end 204 of the damper housing 200. In other cases, an outer side surface portion 228 of the housing wall 208 may be exposed to or along the end 204 of the damper housing.

[0042] The elongated damper rod 216 may protrude outwardly from the damper end wall 222 such that the end 212 of the damper rod assembly is exposed outwardly from the damper housing and is accessible from the outside relative to the damper housing. For example, a connection structure 230 (such as a plurality of threads) may be provided on or along the elongated rod for operatively connecting the gas spring and damper assembly 200 directly or indirectly to an associated vehicle structure, a component of the gas spring assembly GS1, or another component of the gas spring and damper assembly AS1.

[0043] It will be appreciated that the gas spring and damper assembly AS1 may be operatively connected between an associated sprung mass and an unsprung mass of an associated vehicle (or other structure) in any suitable manner. For example, one end of the assembly may be operatively connected to the associated sprung mass, while the other end of the assembly is disposed toward and operatively connected to the associated unsprung mass. Figure 3 As shown, for example, the end 212 of the damper rod assembly 202 may be coupled to a first structural member or upper structural member USC (such as, for example, Figure 1 operatively engaged (directly or indirectly) with the associated vehicle body BDY in the housing and may be secured thereto in any suitable manner. As a non-limiting example, the gas spring and damper assembly AS1 may include an end member assembly EM1 that may be secured to the upper structural component USC and to which one or more components of the gas spring assembly GS1 and / or one or more components of the damper assembly DS1 may be operatively connected. Additionally or alternatively, the damper assembly DP1 may include a mounting bracket 232 disposed along an end 206 of the damper housing 200 that may be secured to a second structural component or lower structural component LSC ( Figure 3 ) (such as Figure 1 The device may be fixed to or along the relevant suspension component SCP in the embodiment and may be fixed thereto in any suitable manner.

[0044] The gas spring assembly GS1 may include a flexible spring member 300 that may extend circumferentially about an axis AX and may be fixed between opposing end members (or end member assemblies) in a substantially fluid-tight manner such that a spring chamber 302 is at least partially defined therebetween. As a non-limiting example, the end member assembly EM1 may include an end member 400 (into which one end of the flexible spring member 300 may be fixed) and an end member 500 (to which the end 212 of the damper rod assembly 202 is operably connected). In addition, or in the alternative, the gas spring assembly GS1 may include an end member assembly 600 that is supported on or along the damper housing 200. The end of the flexible spring member 300 opposite the end member 400 may be fixed on or along the end member assembly 600 in any suitable manner. Furthermore, it should be understood that the end member 600 may be operably supported on or along the damper housing 200 in a suitable manner. As a non-limiting example, the damper assembly DP1 may include a support wall or support wall portion 234 extending radially outward from along the damper housing toward the peripheral edge 236. The support wall portion 234 may include a surface portion 238 facing the end 204 of the damper housing 200 and a surface portion 240 facing the end 206 of the damper housing. The support wall portion 234 may be supported on or along the damper housing in any suitable manner, such as, for example, by one or more flow material joints 242. If included, the end cap 224 may include a cover wall 244 having an end wall portion 246 oriented transverse to the longitudinal axis AX and a side wall portion 248 extending axially about the longitudinal axis. The side wall portion 248 may include an outer side surface portion 226 that faces radially outward and forms the outermost peripheral extent of the damper assembly DP1 along the end 204 of the damper housing.

[0045] It should be understood that the flexible spring member 300 can have any suitable size, shape, structure and / or configuration. In addition, the flexible spring member can be of any type and / or variety, such as a rolling cam type or a spiral bellows type structure. Figures 2 to 9 304, which can be formed in any suitable manner from any suitable material or combination of materials. For example, the flexible wall can include one or more fabric-reinforced elastomeric piles or layers and / or one or more unreinforced elastomeric piles or layers. Typically, one or more fabric-reinforced elastomeric piles and one or more unreinforced elastomeric piles are used together and are formed from a common elastomeric material such as synthetic rubber, natural rubber, or a thermoplastic elastomer. However, in other cases, a combination of two or more different materials, two or more compounds of similar materials, or two or more grades of the same material may be used.

[0046] The flexible wall 304 may extend generally longitudinally between the opposite ends 306 and 308. In addition, the flexible wall 304 may include an outer surface 310 and an inner surface 312. The inner surface may at least partially define the spring chamber 302 of the gas spring assembly GS1. The flexible wall 304 may include an outer or outer tire cord layer (not identified) that at least partially forms the outer surface 310. The flexible wall 304 may also include an inner or inner tire cord layer (not identified) that at least partially forms the inner surface 312. In some cases, the flexible wall 304 may also include one or more reinforcement piles (not shown) disposed between the outer surface 310 and the inner surface 312. The one or more reinforcement piles may have any suitable structure and / or configuration. For example, the one or more reinforcement piles may include one or more lengths of filament material at least partially embedded therein. In addition, it should be understood that, if any, the one or more lengths of filament material may be oriented in any suitable manner. As one example, the flexible wall may include at least one layer or ply of filamentary material having multiple lengths oriented at a bias angle and at least one layer or ply of filamentary material having multiple lengths oriented at the same but opposite bias angle.

[0047] The flexible spring member 300 may include any feature or combination of features suitable for forming a substantially fluid-tight connection with the end member 400 of the end member assembly EM1 and / or suitable for forming a substantially fluid-tight connection with the end member assembly 600. As an example, the flexible spring member 300 may include an open end that is fixed to or along the corresponding end member via one or more crimping rings 314 and 316. Alternatively, a mounting bead (not shown) may be provided along either or both ends of the flexible wall. In some cases, the mounting bead (if any) may optionally include a reinforcing element, such as, for example, an endless annular bead wire. In some cases, the restraining cylinder 318 and / or other components may be provided radially outwardly along the flexible wall 304. In some cases, such components may be fixed to or along the flexible wall in a suitable manner, such as, for example, via one or more backing rings 320.

[0048] As mentioned above, the gas spring and damper assembly AS1 can be arranged between the associated sprung mass and the unsprung mass of the associated vehicle in any suitable manner. For example, one component is operatively connected to the associated sprung mass, while another component is arranged toward and operatively connected to the associated unsprung mass. For example, Figures 2 to 5 As shown, the end member 500 may include one or more fasteners 501 operable to secure the end member assembly EM1 to an upper structural component USC (such as, for example, Figure 1The damper assembly DP1 may be operably connected to the upper structural component via the end member assembly EM1 and may be operably engaged with the end member assembly in any suitable manner. For example, the damper assembly DP1 may include a bushing 250 supported on or along the end member 500, and the damper rod assembly 202 may be secured to the bushing such as, for example, by engaging a connector 252 of the connection structure 230 along the end 212 of the elongated damper rod 216. The bushing 250 may be supported on or along the end member 500 and may be operably secured to the end member in any suitable manner. As a non-limiting example, the bushing 250 may be captured between the end member 500 and an end cap 254, which may be secured to or along the end member in a suitable manner such as, for example, by a retaining ring 256. In some cases, a connector fitting 258 may extend through the end cap 254 or otherwise be disposed on or along the end cap, such as to provide a communicative coupling of electrical and / or pressurized gas systems and / or devices to the gas spring and damper assembly AS1.

[0049] It should be understood that the gas spring and damper assembly AS1 is capable of shifting between an extended state and a compressed state during normal operational use. In some cases, one or more jounce bumpers may be included to inhibit contact between one or more features and / or components of assembly AS1. For example, the damper assembly DP1 may include a jounce bumper 260 positioned on or along the elongated damping rod 216 within the spring chamber 302. It should be understood that the jounce bumper (if provided) may be supported in any suitable manner. As a non-limiting example, the jounce bumper 260 may be supported on the end member assembly 500 to substantially inhibit contact between components of the damper assembly DP1 and the end member assembly 500 during a fully jounced state of the assembly AS1. However, it should be understood that other constructions and / or arrangements may be used alternatively.

[0050] In addition, as described above, the gas spring and damper assembly AS1 may experience or otherwise rotate relative to one another during the displacement between the extended and compressed states. It should be understood that such relative rotation may be detrimental to the flexible spring member 300, and the gas spring and damper assembly typically includes one or more features, components and / or structures operable to isolate such relative rotation from the flexible spring member. For example, in some cases, the operational connection with the upper structural component USC may include one or more rotatable or torsion components. In this case, the end member assembly 600 may be directly supported on or along the support wall of the damper assembly in a substantially fixed rotational position. However, in other cases, the end member assembly EM1 may be fixed on or along the upper structural component USC in a substantially fixed rotational orientation. In this case, the gas spring and damper assembly AS1 may include a torsion isolator 700, which may be supported on or along the support wall portion 234 of the damper assembly DP1. The torsional isolator 700 may include an elastomeric or other compliant body 702 supported between a (relatively) rigid body 704 and a (relatively) rigid body 706. It should be understood that the compliant body 702 may be permanently affixed (i.e., not separable without damage, destruction, or material alteration of at least one component portion) to and / or between the rigid bodies 704 and 706, such as by a cured joint (e.g., vulcanization) and / or a flow of material joint.

[0051] It should be understood that the torsional isolator 700 can be supported between the support wall portion 234 and the end member assembly 600 in any suitable manner. As a non-limiting example, the rigid body 706 can include a surface portion 708 disposed opposite the surface portion 238 of the support wall portion 234. The rigid body 706 can also include one or more mounting posts 710 or other fixing devices that can extend through corresponding holes 262 in the support wall portion 234. In such an arrangement, the rigid body 706 can be supported on the damper assembly DP1 in a substantially fixed position in at least one axial direction and a substantially fixed rotational orientation. The seal 712 can be sealingly disposed between the rigid body 706 and the damper housing 200 so that a substantially fluid-tight arrangement is formed therebetween. In some cases, the rigid body 706 can include an annular recess 714 extending from along the surface portion 708 into the rigid body, and the seal 712 can be disposed in the annular recess together with a base ring 716 that supports the seal to the support wall portion 234 in an axially spaced relationship.

[0052] The rigid body 704 may include a rigid body wall 718 having a flange wall portion 720 oriented transverse to the longitudinal axis AX and a guide wall portion 722 extending axially from the flange wall portion 720 in a direction away from the rigid body 706. The flange wall portion 720 may extend radially outward to an outer peripheral edge 724 and may include a surface portion 726 facing the opposite surface portion 708. The guide wall portion 722 extends axially toward a distal surface portion 728 facing the opposite surface portion 708 and includes an outer side surface portion 730 facing radially outward. The rigid body 704 may be operably connected to the end member assembly 600 so as to maintain a substantially fixed rotational position therebetween. Therefore, the rigid body 704 may include one or more protrusions 732 extending outwardly from the surface portion 726, which are received in corresponding channels 602 in the end member assembly, such as to transfer rotational forces and / or loads to, from, and / or between the rigid body 704 and the end member assembly.

[0053] The seal 734 can be sealingly disposed between the rigid body 704 and the end member assembly 600 so as to form a substantially fluid-tight arrangement therebetween. In some cases, the rigid body 704 can include an annular groove 736 extending into the rigid body, such as from along the outer surface portion 730, and the seal 732 can be at least partially received in the annular groove. However, it should be understood that other constructions and / or arrangements may be used alternatively. During use, the rigid body 706 remains in a substantially fixed rotational position relative to the damper assembly DP1, and the rigid body 704 remains in a substantially fixed rotational position relative to the end member assembly 600. Therefore, the seal 712 and the seal 734 each form a substantially static sealing arrangement between the corresponding components, rather than forming a dynamic sealing arrangement such as can be used in known structures. Thus, rotational displacements that may occur between one or more components of the damper assembly DP1 and one or more components of the gas spring assembly GS1 during use are isolated from (or at least significantly reduced) the flexible spring member 300 by deflection of the compliant body 702, which allows the rigid bodies 704 and 706 to rotate relative to each other about the longitudinal axis AX.

[0054] The end member assembly 600 is a type and kind of what is commonly referred to as a roll-out piston or piston assembly. It should be understood that the end member assembly 600 may include any suitable number of one or more components and / or elements. For example, in the arrangement shown and described herein, the end member assembly 600 includes an end member core 604, which is arranged along the damper housing 200 and supported on the damper housing, such as by a torsion isolator 700 as described above. The end member housing (or housing segment) 606 is supported on the end member core and may include an outer surface 608, along which the rolling cam 322 of the flexible spring member 300 may move when the gas spring and damper assembly AS1 moves between compression and extension conditions. It should be understood that the end member core 604 can be configured to receive and support one or more end member housings and / or housing segments, such as any one of a variety of different sizes, shapes and / or configurations (e.g., outer profiles with different profiles and / or shape combinations).

[0055] In addition, it should be understood that the end member assembly 600 and one or more of its components and / or elements can be formed of any suitable material or combination of materials and can include any suitable number or combination of one or more walls and / or wall portions. For example, the end member core 604 and / or the end member shell segment 606 can be formed of a suitable polymeric material or combination of polymeric materials, such as fiber-reinforced polypropylene, fiber-reinforced polyamide, or an unreinforced (i.e., relatively high-strength) thermoplastic (e.g., polyester, polyethylene, polyamide, polyether, or any combination thereof).

[0056] The end member core 604 is shown extending circumferentially about the axis AX and extending longitudinally between opposite ends 610 and 612. The end member core 604 can include a first or upper mounting section 614 toward the end 610, and the end 308 of the flexible spring member 300 can be operably connected to or along the first or upper mounting section in a suitable manner. For example, the retaining ring 316 can be crimped or otherwise deformed radially inward to form a substantially fluid-tight connection between the end 308 of the flexible spring member 300 and the mounting section 614 of the end member core 604. In this manner, the spring chamber 302 can be at least partially defined by the flexible spring member 300 between the end member 400 and the end member assembly 600, as described above.

[0057] The end member core 604 may include a core wall 616 that extends circumferentially around the axis AX and extends longitudinally between the ends 610 and 612. The core wall 616 may include a first or outer wall portion 618 disposed along the end 610 that terminates at a distal edge 620. In some cases, the outer wall portion 618 may at least partially define an outermost periphery along a longitudinal segment of the end member core 616, such as, for example, along the mounting segment 614. The outer wall portion 618 may optionally include one or more engagement features disposed along its outer surface portion 622, which may be suitable for engaging the end or other surface portion of the flexible spring member 300, thereby enhancing the retention of the flexible spring member and the end member assembly in an assembled condition. As a non-limiting example, the one or more engagement features disposed on or along the outer surface of the outer wall portion 618 may include a plurality of axially spaced annular annular grooves 624. However, it should be understood that other configurations and / or arrangements may be alternatively used. A backing ring 626 , such as, for example, an annular ring formed as a ring of metal or other rigid material, may be disposed radially inwardly of the outer wall portion 618 to provide increased rigidity and / or strength to the crimped connection between the flexible spring member and the end member core formed by the retaining ring 324 .

[0058] In some cases, the outer wall portion 618 can take the form of an annular, ring-shaped wall extending circumferentially around the end member assembly 600. The core wall 616 can also include a second or inner wall portion 628 spaced radially inward from the outer wall portion 618, thereby forming an annular channel 630 therebetween. The inner wall portion 628 can extend circumferentially about the axis AX and can extend axially toward a distal edge 632, which in some cases can be disposed generally aligned with the distal edge 620 of the outer wall portion 618. In this case, the distal edge of the inner wall portion 628 can optionally be disposed in a common plane with the distal edge 620 of the outer wall portion 618. In addition, at least a portion of the inner wall portion 628 can be coextensive with the outer wall portion 618 (i.e., extend in an axially overlapping relationship with each other).

[0059] The core wall 616 of the end member core 604 may also include a second or intermediate section 634 extending from along the upper mounting section 614 in a direction toward the end 612 of the end member core. The intermediate section 634 may include an outer surface portion 636, the size of which is designed to receive and engage one or more end member housings or sections that can be fixed along it in any suitable manner. As an example, the end member housing may include a housing wall 638, which may be divided into or alternatively formed into two or more housing wall sections 606, which may be assembled together around the intermediate section 634. However, it should be understood that other configurations and / or arrangements may be used alternatively. In addition, the housing wall 638 may include a contoured outer surface portion (not numbered) that at least partially forms the outer surface 608 of the end member assembly 600, along which the rolling cam 322 moves during use.

[0060] The core wall 616 of the end member core 604 may also include a third or lower mounting section 640 disposed at or along the end 612, which is sized or otherwise configured to at least partially support the end member assembly 600 on or along the damper assembly DP1 in an axial direction. The core wall 616 may also include an inner surface portion 642 that may at least partially define a channel 644 through the end member core 604. The core wall 616 may optionally include one or more elongated ribs 646 that may be arranged in a circumferentially spaced relationship to each other about the axis AX and may extend longitudinally along the inner surface portion 642. If included, the elongated ribs 646 may be sized to form a sliding fit or a clearance fit along the outer surface 228 of the damper housing 200. Additionally, a wear reducing and / or friction reducing band 648 may be provided along the mounting section 614 , such as may be sized to operatively engage the outer side surface portion 226 of the end cap 224 and / or the outer side surface portion 228 of the housing wall 208 .

[0061] As described above, the end member assembly EM1 is configured to interconnect the flexible spring member 300 of the gas spring assembly GS1 and the damper rod assembly 202 of the damper assembly DP1, as well as to operably connect the gas spring assembly and the damper assembly to associated structural components, such as, for example, the upper structural component USC. The end member 400 and the end member 500 can be connected to each other in a substantially rotationally fixed manner by using one or more protrusions and one or more grooves that engage each other. In the arrangement shown and described herein, the end member 400 includes one or more protrusions and the end member 500 includes one or more grooves. However, it should be understood that alternative constructions in which the end member 400 includes one or more grooves and the end member 500 includes one or more protrusions or any combination thereof are intended to find support in the present subject disclosure.

[0062] End member 400 is shown and described herein as including an end member wall 402 that extends circumferentially about a longitudinal axis AX. End member wall 402 includes a side wall portion 404 having an inner surface portion 406 that faces radially inward. A plurality of protrusions 408 extend inwardly from the inner surface portion 406 toward a distal end 410. The plurality of protrusions are disposed in a spaced relationship with one another about the longitudinal axis AX, and may include a plurality of protrusions having a range from two (2) to twenty (20) protrusions. Protrusions 408 have a protrusion width that may be in a direction transverse to the longitudinal axis AX, such as in Fig.14 denoted by, for example, reference dimension PWD. The end member 400 may also include an outer surface portion 412 sized to receive the end 306 of the flexible spring member so as to be secured along it in a suitable manner, such as, for example, by a crimping ring 314. One or more securing grooves 414 may be disposed on or along the outer surface portion 412. In some cases, the outer surface portion and any grooves included thereon may be disposed on or along the sidewall portion 404. Alternatively, the end member wall 402 may include a sidewall portion 416 disposed radially outward of the sidewall portion 404 so that a channel 418 may be disposed between them. In some cases, a backing ring 420 may be disposed radially inward of the sidewall portion 416 to provide additional strength and / or rigidity to the end member 400. In some cases, the end wall portion 422 may be disposed transversely to the longitudinal axis AX and may extend between and interconnect the sidewall portions 404 and 416.

[0063] End member 500 is shown and described herein as including an end member wall 502 extending circumferentially around a longitudinal axis AX. End member wall 502 includes a side wall portion 504 that extends coextensively with at least side wall portion 404 in the assembled state of end member assembly EM1. Side wall portion 504 may include one or more slots or grooves 506 formed along it. In some cases, slots or grooves 506 may extend in an axial direction or otherwise be oriented so that their openings (not numbered) face in a radial direction. Groove 506 has a groove width GWD ( Fig.18) and is sized to receive one of the plurality of protrusions such that a transition fit or interference fit is formed between the groove and the corresponding protrusion. The end member wall 502 also includes a flange wall portion 508 extending outwardly from along the side wall portion 504 to the peripheral edge 510. The end wall portion 512 can be disposed radially inwardly of the side wall portion 504 and can at least partially define a recess 514 in which the bushing 250 is received. The end wall portion 512 can extend radially inwardly toward an inner peripheral edge 512E that at least partially defines an opening or passage 512P through the end member 500. In some cases, a seal 516 can be disposed along the side wall portion 504 in sealing engagement with the end cap 254. The side wall portion 504 can optionally include an annular groove 518 extending into the side wall portion that is sized to at least partially receive the seal 516. Additionally, a seal 520 can be disposed between the end members 400 and 500, and it should be appreciated that any suitable configuration and / or arrangement can be used to receive and retain the seal 520 in sealing engagement between the end members such that a substantially fluid-tight seal is maintained therebetween. As a non-limiting example, the sidewall portion 504 can have an outer surface portion 522 along which an annular groove 524 can be formed that is sized to at least partially receive the seal 520.

[0064] As used herein with reference to certain features, elements, components and / or structures, numerical ordinal numbers (e.g., first, second, third, fourth, etc.) may be used to represent different single or otherwise identify certain features, elements, components and / or structures, and do not imply any order or sequence unless expressly specified by the claim language. In addition, the term "transverse" etc. is interpreted broadly. Because of this, the term "transverse" etc. may include a wide range of angular orientations, including but not limited to approximately vertical angular orientations. In addition, the terms "circumferential", "circumferentially", etc. may be interpreted broadly, and they may include but are not limited to circular shapes and / or structures. In this regard, the terms "circumferential", "circumferentially", etc. may be synonymous with terms such as "peripheral", "peripherally", etc.

[0065] In addition, the phrase "flowing material joint" and the like, if used herein, may be interpreted to include any joint or connection in which a liquid or other flowable material (e.g., molten metal or a combination of molten metals) is arranged or otherwise presented between adjacent components and used to form a fixed and substantially fluid-tight connection therebetween. Examples of processes that can be used to form such flowing material joints include, but are not limited to, welding processes, brazing processes, and soldering processes. In such cases, in addition to any materials derived from the components themselves, one or more metallic materials and / or alloys may be used to form such flowing material joints. Another example of a process that can be used to form a flowing material joint includes applying, depositing, or otherwise presenting an adhesive between adjacent components for forming a fixed and substantially fluid-tight connection therebetween. In such cases, it should be understood that any suitable adhesive material or combination of materials may be used, such as, for example, a one-component and / or two-component epoxy resin.

[0066] Furthermore, the term "gas" as used herein refers to any gaseous or aerosol fluid in a broad sense. Most commonly, air is used as the working medium for gas spring devices such as those described herein and suspension systems and other components thereof. However, it should be understood that any suitable gaseous fluid may be used.

[0067] It should be recognized that many different features and / or components are shown in the embodiments shown and described herein, and no one embodiment is explicitly shown and described as including all such features and components. Therefore, it should be understood that the subject matter of the present disclosure is intended to cover any and all combinations of the different features and components shown and described herein, and any suitable arrangement of features and components may be used in any combination without restriction. Therefore, it should be clearly understood that claims involving any such combination of features and / or components, whether or not specifically embodied herein, are intended to find support in the present disclosure. To assist the Patent Office and any reader of this application and any resulting patent used to interpret the claims attached to this application, the applicant does not intend that any of the attached claims or any claim element invoke 35 U.S.C. 112(f) unless the words "device for..." or "step for..." are expressly used in a particular claim.

[0068] Therefore, although the subject matter of the present disclosure is described with reference to the above-mentioned embodiments and considerable emphasis is given herein to the structure and structural interrelationships between the component parts of the disclosed embodiments, it should be understood that other embodiments can be constructed and that many changes can be made to the embodiments shown and described without departing from the principles of the present invention. Obviously, other aspects will be modified and changed after reading and understanding the above-mentioned specific embodiments. Therefore, it should be clearly understood that the above-mentioned descriptive issues are only interpreted as illustrative and not restrictive of the subject matter of the present disclosure. Because of this, it is intended that the subject matter of the present disclosure be understood to include all such variations and changes.

Claims

1. An end member assembly (EM1) having a longitudinal axis (AX) and configured to interconnect an associated flexure spring member (300) of an associated gas spring assembly (GS1) and an associated damper rod assembly (202) of an associated damper assembly (DP1) to an associated structural component (USC), the end member assembly (EM1) comprising: a first end member (400), the first end member comprising a first end member wall (402), the first end member wall (402) comprising a first side wall portion (404) having a first inner side surface portion (406) extending therealong, a plurality of protrusions (408) disposed in circumferentially spaced relation to one another about the longitudinal axis (AX), the plurality of protrusions (408) extending longitudinally and projecting radially beyond the first inner side surface portion (406) to an end surface portion (410); and a first outer side surface portion (412) dimensioned to receivably engage an associated flexible spring member (300); a second end member (500), the second end member comprising a second end member wall (502) of an associated damper rod assembly (202) operably connected to an associated damper assembly (DP1), the second end member wall (502) comprising a side wall portion (504) extending axially coextensively with the first side wall portion (404) of the first end member wall (402) and an outer flange wall portion (508), the side wall portion (504) being oriented transversely to the side wall portion (504) and extending outwardly therefrom to an outer peripheral edge (510), the side wall portion (504) comprising a second side surface portion (522) and a plurality of grooves (506) extending longitudinally and radially beyond the second side surface portion (522), wherein each of the plurality of grooves (506) is sized to receive a portion of one of the plurality of protrusions (408), the plurality of grooves (506) being less than the plurality of protrusions (408); as well as a plurality of fasteners (501) disposed along the outer flange wall portion (508) of the second end member (500) and operable to secure the end member assembly (EM1) to or along an associated structural component (USC), The second end member (500) is engaged with the first end member (400) so that the second side surface portion (522) of the second end member (500) is axially coextensive with the first inner side surface portion (406) of the first end member (400), each of a first number of the plurality of protrusions (408) extends into a different groove among the plurality of grooves (506), so that the axial engagement of the first number of the plurality of protrusions (408) with a corresponding one of the plurality of grooves (506) maintains the first end member and the second end member (400; 500) in a rotationally fixed relationship relative to each other, a remaining number of the plurality of protrusions (408) is arranged between adjacent grooves among the plurality of grooves (506), so that the remaining number of the plurality of protrusions (408) are not rotationally constrained by the plurality of grooves (506), and the end surface portions (410) of the remaining number of protrusions (408) are adjacently engaged with the second side surface portion (522) of the second end member (500).

2. An end member assembly (EM1) according to claim 1, wherein the first outer side surface portion (412) includes one or more fixing grooves (414), and the one or more fixing grooves (414) are arranged on or along the first outer side surface portion (412), and the size of the first outer side surface portion is designed to fix the relevant end (306) of the relevant flexible spring member (300) along it.

3. The end member assembly (EM1) of claim 1, wherein the plurality of protrusions (408) comprises a plurality of protrusions (408) in a range from two to twenty protrusions (408).

4. An end member assembly (EM1) according to claim 1, wherein the plurality of protrusions (408) extend radially inward beyond the first inner surface portion (406), and the plurality of grooves (506) extend axially along the second side surface portion (522), and the second side surface portion has an open side facing radially outward.

5. The end member assembly (EM1) according to claim 4, wherein the plurality of grooves (506) are circumferentially spaced apart from each other around the longitudinal axis (AX) along the second side surface portion (522) of the second end member (500).

6. The end member assembly (EM1) of claim 5, wherein the plurality of grooves (506) comprises a plurality of grooves (506) in a range from two to twenty grooves (506).

7. The end member assembly (EM1) according to claim 5, wherein the plurality of grooves (506) is less than the plurality of protrusions (408), so that one or more protrusions of the plurality of protrusions (408) are arranged between adjacent grooves of the plurality of grooves (506).

8. An end member assembly (EM1) according to any one of claims 5 to 7, wherein each of the plurality of grooves (506) has a groove width (GWD), and each of the plurality of protrusions (408) has a protrusion width (PWD), and the protrusion width (PWD) of at least one of the plurality of protrusions (408) is equal to or greater than the groove width (GWD), so that when at least one of the plurality of grooves (506) is engaged with the at least one of the plurality of protrusions (408), one of a transition fit and an interference fit is formed therebetween.

9. An end member assembly (EM1) according to claim 1, wherein the first side wall portion (404) of the first end member wall (402) is a first inner wall portion, the first inner surface portion (406) is arranged along the first inner wall portion and the plurality of protrusions (408) extend from the first inner wall portion in a radially inward direction.

10. An end member assembly (EM1) according to claim 9, wherein the first end member wall (402) includes a first outer side wall portion (416), and the first outer side surface portion (412) is provided with a plurality of annular retaining grooves (414) along the first outer side wall portion, and the plurality of annular retaining grooves extend radially inward into the first outer side wall portion (416) to engage the associated flexible spring member (300).

11. An end member assembly (EM1) according to claim 10, wherein the first outer side wall portion (416) is spaced radially outward from the first inner side wall portion and axially coextensive with the first inner side wall portion, so that an annular channel (418) is at least partially defined between the first outer side wall portion and the first inner side wall portion.

12. An end member assembly (EM1) according to claim 11, wherein the first end member wall (402) includes an end wall portion (422), which is oriented transversely to the longitudinal axis (AX) and interconnects the first inner wall portion and the first outer wall portion (416) so that the annular channel (418) has an open end opposite to the end wall portion (422).

13. An end member assembly (EM1) according to claim 1, wherein the second end member wall (502) includes an inner flange wall portion (512), which is oriented transversely to the side wall portion (504) and extends inwardly from the side wall portion to an inner peripheral edge (512E), and the inner peripheral edge at least partially defines a channel (512P) through the second end member (500), and the associated damper assembly (DP1) can extend through the channel.

14. The end member assembly (EM1) according to claim 1, further comprising a seal (520) disposed between the first end member (400) and the second end member (500).

15. The end member assembly (EM1) according to claim 1, wherein the first end member (400) is at least partially formed of a first material, and the second end member (500) is at least partially formed of a second material different from the first material.

16. A gas spring and damper assembly (AS1), comprising: A damper assembly (DP1) having a longitudinally extending axis (AX) and comprising: A damper housing (200) comprising a housing wall (208) extending axially between opposing first and second ends (204, 206), the housing wall (208) at least partially defining a damping chamber (210) containing a volume of damping fluid (220); and, a damper rod assembly (202), the damper rod assembly comprising an elongated damper rod (216) and a damper piston (218) fixed along the elongated damper rod (216), the damper rod assembly (202) being operatively interengaged with the damper housing (200) for reciprocal displacement relative to the damper housing, wherein the damper piston (218) is disposed within the damping chamber (210) and at least a portion of the elongated damper rod (216) projects axially outwardly from the first end (204) of the damper housing (200); and, A gas spring assembly (GS1), the gas spring assembly being arranged in an axially coextensive relationship with at least a portion of the damper assembly (DP1), the gas spring assembly (GS1) comprising: a flexible spring member (300) extending circumferentially about the longitudinal axis (AX) and extending longitudinally between opposite first and second ends (306 and 308) such that a spring chamber (302) is at least partially defined between the first and second ends; a first end member assembly, the first end member assembly being an end member assembly (EM1) according to any one of claims 1 to 15, the first end member assembly being operatively connected to the elongated damper rod (216) and operatively fixed to the first end (306) of the flexible spring member (300) so as to form a fluid-tight connection therebetween; and, A second end member assembly (600) is supported on the damper housing (200) and operatively secured to the second end (308) of the flexible spring member (300) such that a fluid-tight connection is formed therebetween.

17. A suspension system (100), comprising: A compressed gas system (108), the compressed gas system comprising a compressed gas source (110; 120) and a control device (112); as well as, At least one gas spring and damper assembly (AS1) according to claim 16, wherein the at least one gas spring and damper assembly is arranged to be fluidly connected to the compressed gas source (110; 120) through the control device (112) so that compressed gas can be selectively transmitted into and out of at least the spring chamber (302).

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