End member assembly and gas spring assembly including the end member assembly

Abstract

The present disclosure provides an end member assembly that is sized to be fixed to an associated flexible spring member. The end member assembly includes a first end member segment, a second end member segment, and a third end member segment. The first end member segment includes a first peripheral wall portion. The second end member segment includes a second peripheral wall portion. The second end member segment is positioned to be adjacently engaged with the first end member segment so that a groove extends circumferentially around the first end member segment and the second end member segment between the first peripheral wall portion and the second peripheral wall portion. The third end member segment is in-situ injection molded together with the first end member segment and the second end member segment so that the third end member segment extends circumferentially around the first end member segment and the second end member segment within the groove. The present disclosure also includes a gas spring assembly and a vehicle suspension system.

Description

Background Art

[0001] The subject matter of the present disclosure generally relates to gas spring device technology, and more specifically to an end member assembly for a gas spring, the end member assembly including two polymer wall portions, wherein a third polymer wall portion is injection molded separately from the two polymer wall portions in situ, so that the third polymer wall portion surrounds, spans over, and / or otherwise forms a substantially fluid-tight joint between the first polymer wall portion and the second polymer wall portion. A gas spring assembly including one or more such end member assemblies is also included. In some cases, such a gas spring assembly can be coextensively assembled with a damper to form a gas spring and damper assembly. In addition, a vehicle suspension system including one or more such gas spring assemblies (and / or gas spring and damper assemblies) is included.

[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 devices and a plurality of damping devices that 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 spring devices 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 inputs and movements of the sprung mass, such as, for example, road surface inputs that occur under dynamic operation of the vehicle. In many cases, the damping devices may be liquid-filled hydraulic dampers (e.g., conventional shock absorbers or shock struts) of known construction. However, in other cases, the damping devices may be of a type and kind that utilizes a gaseous fluid as a working medium rather than a liquid.

[0005] In many applications involving vehicle suspension systems, it is desirable to utilize spring elements having as low a spring rate as possible because the use of lower spring rate elements may provide improved ride quality and comfort compared to spring elements having higher spring rates. That is, it is well understood in the art that the use of spring elements having higher spring rates (i.e., stiffer springs) will transfer a greater magnitude of road input to the sprung mass of the vehicle, and this generally results in a bumpier and less comfortable ride. Conversely, the use of spring elements having lower spring rates (i.e., softer and more compliant springs) will transfer a smaller magnitude of road input to the sprung mass, and therefore will provide a more comfortable ride.

[0006] In some cases, the spring device of a vehicle suspension system will include a spring that utilizes pressurized gas as the working medium of the device. Typically, the spring rate of the gas spring can be reduced by increasing the volume of compressed gas operatively associated with the gas spring, thereby improving ride comfort. This is typically achieved by utilizing an end member that defines an additional chamber, cavity, or volume filled with pressurized gas that is in fluid communication with the main spring chamber of the gas spring. However, this type of end member can be challenging to manufacture as a single integral component. Therefore, in many cases, such end members are assembled from multiple components that are fixed together so that a substantially fluid-tight joint is formed therebetween.

[0007] Unfortunately, many of the assembly techniques currently used to manufacture such multi-component end members suffer from high manufacturing costs, such as may be due to the handling and processing of including and installing seals and / or components during the joining process. In addition, in some cases, it is challenging to create and maintain a strong and substantially fluid-tight joint between components, and sometimes results in undesirable loss of compressed gas or degradation of other performance characteristics of the resulting assembly. Therefore, it is believed that it is desirable to develop structures that can help overcome the aforementioned and / or other shortcomings of known end member assemblies, and / or otherwise advance the art 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 segment and a second end member segment, the first end member segment having a first segment wall, the first segment wall including a first peripheral wall portion, the second end member segment having a second segment wall, the second segment wall including a second peripheral wall portion. The second end member segment can be positioned to engage adjacently with the first end member segment so that a groove extends circumferentially around the first end member segment and the second end member segment between the first peripheral wall portion and the second peripheral wall portion. A third end member segment having a third segment wall can be in-situ injection molded with the first end member segment and the second end member segment so that the third end member segment extends circumferentially around the first end member segment and the second end member segment within the groove.

[0009] One example of a gas spring assembly according to the disclosed subject matter can have a longitudinal axis and can include a flexible spring member extending circumferentially about the longitudinal axis and extending longitudinally between opposing first and second ends such that a spring chamber is at least partially defined between the first and second ends. The first end member assembly according to the preceding paragraph can be operatively secured to the first end of the flexible spring member such that a substantially fluid-tight connection is formed therebetween. The second end member assembly can be operatively secured to the second end of the flexible spring member such that a substantially fluid-tight connection is formed therebetween.

[0010] One example of a gas spring and damper assembly according to the presently disclosed subject matter may include a gas spring assembly and a damper assembly according to the preceding paragraph, wherein the gas spring assembly is disposed axially coextensive with at least a portion of the damper assembly.

[0011] 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.

[0012] An example of a method of manufacturing an end member assembly according to the subject matter of the present disclosure may include injecting a first amount of polymer material into a first mold cavity at least partially defined by a first first mold segment and a second first mold segment, thereby molding a first end member segment. The method may also include injecting a second amount of polymer material into a second mold cavity at least partially defined by a first second mold segment and a second second mold segment, thereby molding a second end member segment, which is separated from the first end member segment. The method may also include separating the first first mold segment from the second first mold segment, thereby exposing a portion of the first end member segment, while the first end member segment remains in place in the second first mold segment. The method may also include separating the first second mold segment from the second second mold segment, thereby exposing a portion of the second end member segment, while the second end member segment remains in place in the second second mold segment. The method may also include introducing the in-situ first end member segment in the second first mold segment into the in-situ second end member segment in the second second mold segment, thereby forming a groove that extends circumferentially around the first end member segment and the second end member segment. The method may also include injecting a third amount of polymeric material in-situ into the groove between the first end member segment and the second end member segment, thereby forming a third end member segment that operatively connects the first end member segment and the second end member segment to form a substantially fluid-tight joint therebetween. BRIEF DESCRIPTION OF THE DRAWINGS

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

[0014] Figure 2 is a side view of one example of a gas spring and damper assembly including an exemplary gas spring assembly according to the presently disclosed subject matter.

[0015] Figure 3 yes Figure 2 Top plan view of the gas spring and damper assembly.

[0016] Figure 4 It is along Figure 3 The line 4-4 in Figure 2 and Figure 3 Cross-sectional side view of the gas spring and damper assembly.

[0017] Figure 5 is a top perspective view of an end member assembly according to the disclosed subject matter, such as for example Figures 2 to 4 End member assembly shown.

[0018] Figure 6 yes Figures 2 to 5Bottom perspective view of the end member assembly in FIG.

[0019] Figure 7 yes Figures 2 to 6 A bottom perspective view of one end member component of the end member assembly is shown.

[0020] Figure 8 yes Figures 2 to 6 A top perspective view of another end member component of the end member assembly is shown.

[0021] Fig. 9 is a cross-sectional side elevation view showing the Figures 2 to 8 The two end member parts.

[0022] Fig.10 is a cross-sectional side elevation view showing the in-situ in-situ in respective individual mold sections. Fig. 9 Two end member components of the embodiment of the present invention, wherein a portion of each individual mold is removed.

[0023] Fig.11 is a cross-sectional side elevation view showing the Fig. 9 and 10 The invention relates to two end member components of the present invention, wherein the respective separate mold sections are brought together for in-situ manufacturing of a third end member component.

[0024] Fig.12 yes Fig.11 An enlarged view of a portion of the end member component and mold segment identified as detail 12 in FIG.

[0025] Fig.13 is an enlarged view of a cross-sectional profile of an exemplary cavity for in-situ fabrication of a third end member component.

[0026] Fig.14 is an enlarged view of a third end member component fabricated in situ along with the other two end member components. DETAILED DESCRIPTION

[0027] 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.

[0028] Figure 1An 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 and / 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 the associated vehicle in any suitable manner. The suspension system includes one or more gas spring assemblies in accordance with the subject matter of the present disclosure and one or more damper assemblies operatively connected between the sprung mass and the unsprung mass and together allow the sprung mass and the unsprung mass of the associated vehicle to move relative to each other in a controlled manner, as discussed above.

[0029] Depending on the desired performance characteristics and / or other factors, in some cases, one or more gas spring assemblies may be provided and installed separately from one or more damper assemblies. Additionally or alternatively, the gas spring assembly may be assembled with the damper assembly so that at least a portion of the gas spring assembly is axially coextensive with the damper assembly to form a so-called gas spring and damper assembly. It should be understood that the gas spring assembly and its components according to the subject matter of the present disclosure are shown and described herein with particular reference to the gas spring and damper assembly. However, it should be recognized and understood that such a construction is optional, and the gas spring assembly (and its components and assemblies) according to the subject matter of the present disclosure are not intended to be limited to use in a gas spring and damper assembly.

[0030] like Figure 1 As shown, the suspension system 100 may include a plurality of gas spring assemblies 102 operatively connected between a sprung mass and an unsprung mass of a vehicle. Additionally, the suspension system 100 may include a plurality of damper assemblies 104 operatively connected between a sprung mass and an unsprung mass of a vehicle. Depending on the desired performance characteristics and / or other factors, the suspension system may include any suitable number of one or more gas spring assemblies and one or more damper assemblies. Additionally, the one or more gas spring assemblies and the one or more damper assemblies may be operatively connected to, along, or otherwise connected between the sprung mass and the unsprung mass in any suitable manner. As a non-limiting example, the gas spring assembly 102 and the damper assembly 104 may optionally be operatively connected in an axially coextensive arrangement to form one or more gas spring and damper assemblies 106, which may then be operatively connected to, along, or otherwise connected between the sprung mass and the unsprung mass as a unit.

[0031] For example, in Figure 1In the illustrated arrangement, the suspension system 100 includes four gas spring and damper assemblies 106, 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 1 As shown, the gas spring and damper assembly 106 is supported between the suspension component SCP and the body BDY of the associated vehicle VHC. It should be appreciated that the gas spring assembly 102 is shown and described herein as having a rolling cam 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.

[0032] 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 110 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).

[0033] The valve assembly 112 communicates with the gas springs 102 and / or dampers 104 of the assembly 106 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.

[0034] 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 106 and exhausting compressed gas from the gas spring and damper assembly. The controller 126 may be of any suitable type, kind, and / or configuration.

[0035] 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.

[0036] Having described an example of a suspension system (e.g., suspension system 100) that may include a gas spring assembly according to the subject matter of the present disclosure, Figures 2 to 4 An example of a gas spring and damper assembly including such a gas spring 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 106 in the embodiment of the present invention are shown to include a gas spring (or gas spring assembly) GS1 (such as may correspond to, for example, Figure 1 ) and a damper (or damper assembly) DP1 (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 respect to one another and may be operatively secured to one another in any suitable manner, such as, for example, as described below. Figure 4 As shown, a longitudinal axis AX extends longitudinally along the assembly AS1.

[0037] 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 a housing end 204 and a housing end 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.

[0038] 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.

[0039] 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.

[0040] 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 2 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 assembly GS1 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 and / or one or more components of the damper assembly DS1 are operatively connected. Additionally or alternatively, the damper assembly DPI 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 2 ) (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.

[0041] 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 segment 400 to which one end of the flexible spring member 300 may be fixed, an end member segment 500 to which the end 212 of the damper rod assembly 202 may be operatively connected, and an end member segment 600 that is injection molded in situ with the end member segment 400 and the end member segment 500. The gas spring assembly GS1 may also include an end member 700 supported on or along the damper housing 200. The end of the flexible spring member 300 opposite the end member assembly EM1 may be fixed on or along the end member 700 in any suitable manner. In addition, it should be understood that the end member 700 can be operatively supported on or along the damper housing 200 in a suitable manner. As a non-limiting example, the damper assembly DP1 can 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 can 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 can 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 can include a cap 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 can 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.

[0042] 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 4 304, 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.

[0043] 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, wherein the inner surface at least partially defines 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.

[0044] The flexible spring member 300 may include any feature or feature combination suitable for forming a substantially fluid-tight connection with the end member segment 400 of the end member assembly EM1 and / or suitable for forming a substantially fluid-tight connection with the end member 700. As an example, the flexible spring member 300 may include an open end, which is fixed to the corresponding end member or along the corresponding end member via one or more crimping rings 314 and 316. Alternatively, a mounting bead (not shown) may be arranged 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 constraint cylinder 318 and / or other components may be arranged radially outward along the flexible wall 304. In some cases, such components may be fixed to the flexible wall or along the flexible wall in a suitable manner, such as, for example, via one or more backing rings 320.

[0045] 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 4 As shown, the end member segment 500 may include one or more fasteners 502 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 by 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 segment 500, and the damper rod assembly 202 may be fixed 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 segment 500 and may be operably fixed to the end member segment in any suitable manner. As a non-limiting example, the bushing 250 may be captured between the end member segment 500 and the end cap 254, which may be fixed on or along the end member segment 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 compressed gas systems and / or devices to the gas spring and damper assembly AS1.

[0046] 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 buffers may be included to inhibit contact between one or more features and / or components of the assembly AS1. For example, the damper assembly DP1 may include a jounce buffer 260 positioned on or along the elongated damper rod 216 within the spring cavity 302. It should be understood that the jounce buffer (if provided) may be supported in any suitable manner. As a non-limiting example, the jounce buffer 260 may be supported on or along the end member segment 400 of the end member assembly EM1 to substantially inhibit contact between components of the damper assembly DP1 and the end member segment 400 during the full jounce state of the assembly AS1. However, it should be understood that other constructions and / or arrangements may be used alternatively.

[0047] In addition, it should be understood that in some cases, during the process of the gas spring and damper assembly AS1 moving between the extended state and the compressed state, the components of the gas spring and damper assembly may experience or otherwise undergo relative rotation. It should be understood that such relative rotation may be detrimental to the flexible spring member 300 and / or other components, and the gas spring and damper assembly generally includes one or more features, components and / or structures that can be operated to isolate such relative rotation from the flexible spring member. For example, in some cases, the operational connection with the upper structure component USC may include one or more rotatable or torsion components. In such cases, the end member 700 can 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 can be fixed on or along the upper structure component USC in a substantially fixed rotational orientation. In such cases, the gas spring and damper assembly AS1 can include a torsion isolator 800, which can be supported on or along the support wall portion 234 of the damper assembly DP1. The torsional isolator 800 may include an elastomeric or compliant body 802 supported between a (relatively) rigid body 804 and a (relatively) rigid body 806. It should be understood that the compliant body 802 may be permanently fixed (i.e., not separable without damage, destruction, or material change of at least one component portion) to and / or between the rigid body 804 and the rigid body 806, such as by a cured joint (e.g., vulcanization) and / or a flowing material joint. It should be understood that the torsional isolator 800 may be supported between the support wall portion 234 and the end member 700 in any suitable manner.

[0048] The end member 700 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 700 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 700 includes an end member core 702, which is arranged along the damper housing 200 and supported on the damper housing, such as by a torsion isolator 800 as described above. The end member housing (or housing segment) 704 is supported on the end member core and may include an outer surface 706, along which the rolling cam 322 of the flexible spring member 300 may move when the gas spring and damper assembly AS1 moves between the compressed and extended states. It should be understood that the end member core 702 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).

[0049] In addition, it should be understood that the end member 700 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 702 and / or the end member shell segment 704 can be formed of a suitable polymeric material or combination of polymeric materials, such as, for example, 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).

[0050] The end member core 702 is shown extending circumferentially about the axis AX and extending longitudinally between opposite ends 708 and 710. The end member core 702 may include a core wall 712 extending circumferentially about the axis AX, having a mounting wall portion 714 toward the end 708, to which or along which the end 308 of the flexible spring member 300 may be operatively connected in a suitable manner. For example, the retaining ring 316 may be crimped or otherwise deformed radially inwardly to form a substantially fluid-tight connection between the end 308 of the flexible spring member 300 and the mounting wall portion 714 of the end member core 702. In this manner, the spring chamber 302 may be at least partially defined by the flexible spring member 300 between the end member segment 400 and the end member 700.

[0051] 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, and to operatively connect the gas spring assembly and the damper assembly to associated structural components, such as, for example, the upper structural component USC. As discussed above, the end member assembly EM1 is at least partially formed by the end member segments 400, 500, and 600, which will be described in conjunction with the end member segments 400 and 500 below. Figures 2 to 14 End member assembly EM1 includes an end member chamber EMC defined at least in part by one or more of end member segments 400, 500, and / or 600, wherein the end member chamber is arranged in fluid communication with spring chamber 302 in a suitable manner, as discussed below.

[0052] The end member segment 400 extends axially between an end 402 disposed away from the end member segment 500 and an end 404 disposed toward the end member segment 500. The end member segment 400 includes a segment wall 406, which is preferably formed at least in part of a polymeric material by an injection molding process and can include any suitable number of walls and / or wall portions. For example, the segment wall 406 can include an end wall portion 408, which is oriented transversely to the longitudinal axis AX and extends peripherally toward an outer side wall portion (or peripheral wall portion) 410, which extends axially from and along the end wall portion 408 toward a distal edge 412. The segment wall 406 can also include an inner side wall portion 414, which is spaced apart from the outer side wall portion at the inner peripheral side of the outer side wall portion 410 and extends axially from and along the end wall portion 408 toward a distal edge 416. The end member segment 400 may include a chamber portion 418 that is at least partially defined by the segment wall 406 between the outer sidewall portion 410 and the inner sidewall portion 414 and at least partially defines the end member chamber EMC. In some cases, one or more openings 420 may be optionally disposed on or along the inner sidewall portion 414, such as may be adapted to allow fluid communication between the end member chamber EMC and the spring chamber 302. In addition, in some cases, a communication port 422 may extend through the end wall portion 408, such as may be adapted to operatively connect a pneumatic accessory or other connector to, for example, the end member segment 400. In addition, in some cases, one or more connector wall portions 424 may extend between the outer sidewall portion 410 and the inner sidewall portion 414 and operatively connect the outer sidewall portion and the inner sidewall portion. If included, a plurality of connector wall portions 424 may be circumferentially spaced from each other around the longitudinal axis AX.

[0053] The segment wall 406 can also include a mounting wall portion 426 that extends from and along the end wall portion 408 in a direction toward the end 402 to a distal edge 428. The mounting wall portion 426 can include an outer surface portion 430 that is dimensioned to receptively engage the end 306 of the flexible spring member 300. As discussed above, the end 306 of the flexible spring member can be secured to or along the end member segment 400 in any suitable manner, such as, for example, by a crimp ring 314. In some cases, the mounting wall portion 426 can include one or more axially spaced endless annular grooves 432 formed there along, such as can be adapted to abuttingly engage the end 306 of the flexible spring member 300. In some cases, a backing ring 434 can be disposed on or along the mounting wall portion 426 radially inward of the outer surface portion 430. If provided, it should be understood that the backing ring 434 can take the form of an annular ring formed of a material that is much more rigid than the material of the segment wall 406 (e.g., a metallic material versus a polymeric material). In some cases, the backing ring 434, if included, can be installed on or along the mounting wall portion 426 after the mounting wall portion is molded or otherwise formed. In other cases, the backing ring 434 can be overmolded with the segment wall 406 during the process of molding or otherwise forming the end member segment 400.

[0054] like Figures 8 to 14 As shown, the outer sidewall portion 410 includes an end surface portion 436 disposed along a distal edge 412, which is oriented transversely to the longitudinal axis AX. The end surface portion 436 extends radially outward to a peripheral edge surface portion 438. The segment wall 406 also includes a protruding wall portion 440, which extends axially outward from and along the end surface portion 436 in a direction toward the distal edge 442. In some cases, the protruding wall portion 440 extends circumferentially around the end member segment 400, and is spaced apart from the peripheral edge surface portion 438 on the inner peripheral side thereof, so that at least some of the end surface portions 436 (identified by reference numeral 436A) are disposed on the inner peripheral side of the protruding wall portion 440, and some of the end surface portions 436 (identified by reference numeral 436B) are disposed on the outer peripheral side of the protruding wall portion. In some cases, an alignment or assembly structure may be included on or along end member segment 400, such as may be adapted to positively engage with a corresponding alignment or assembly structure of end member segment 500. Figure 4 and Figures 8 to 14In the exemplary arrangement shown, the segment wall 406 may optionally include a projecting wall portion 444 that extends axially outward from and along the end surface portion 436 in a direction toward the distal edge 446. If included, the projecting wall portion 444 may extend circumferentially around the end member segment 400, spaced apart from the peripheral edge surface portion 438 on an inner peripheral side thereof, such that at least some of the end surface portion 436 is disposed on an outer peripheral side of the projecting wall portion 444. In a preferred arrangement, the projecting wall portion 444 is also spaced apart from the projecting wall portion 440 on an inner peripheral side thereof.

[0055] In a preferred arrangement, the segment wall 402 of the end member segment 400 can be formed in an injection mold (such as in Fig. 9 In addition, it should be understood that the segment wall 402 can be molded from any suitable polymeric material or combination of polymeric materials, such as, for example, fiber-reinforced polypropylene, fiber-reinforced polyamide, or unreinforced (i.e., relatively high-strength) thermoplastics (e.g., polyester, polyethylene, polyamide, polyether, or any combination thereof).

[0056] Reference now Figure 4 , Figure 5 , Figure 7 and Figures 9 to 14 , the end member segment 500 extends axially between an end 504 disposed away from the end member segment 400 and an end 506 disposed toward the end member segment 400. In some cases, the end member segment 500 can optionally include a mounting body (or mounting insert) 508. With or without the mounting body, the end member segment 500 includes a segment wall 510 that is at least partially formed of a polymeric material, such as can be formed by an injection molding process as discussed below. In some cases, the segment wall 510 can be overmolded onto the mounting body 508, such as by an injection molding process as discussed below (if included). If included, the mounting body 508 can be formed of a material that is much more rigid than the material of the segment wall 510 (e.g., a metallic material versus a polymeric material).

[0057] As a non-limiting example, the mounting body 508, if included, can include a body wall 512 having a side wall portion 514 extending from a distal edge 516 disposed along the end 504 to an end wall portion 518 oriented transverse to the longitudinal axis AX. The end wall portion 518 includes an opening 520 through which the end 212 of the elongated damper rod 216 extends. The side wall portion 514 and the end wall portion 518 can at least partially define a recess 522 within the mounting body 508 that is sized to receive the bushing 250, which can be captured between the end wall portion 518 and the end cap 254, such as, for example, by the retaining ring 256 operatively engaging an annular groove 524 formed along the side wall portion 514 toward the distal edge 516.

[0058] The main body wall 512 of the mounting body 508 also includes a flange wall portion 526, which extends from and along the side wall portion 514 toward the peripheral edge 528 to the peripheral side. The fastener 502 is fixed on the flange wall portion 526 or fixed along the flange wall portion in a suitable manner, and is spaced apart from the inner peripheral side of the peripheral edge 528 and the peripheral edge. In the exemplary arrangement shown, the fastener 502 protrudes axially outward from the flange wall portion 526 in the direction away from the end 506 of the end member segment 500. However, it should be understood that other constructions and / or arrangements can be used alternatively. As indicated above, in a preferred construction, the segment wall 510 is overmolded on the mounting body 508 so that at least a portion of the main body wall 512 is wrapped or otherwise covered by the segment wall 510. In addition, any suitable combination of wall portions and / or other structures can be used to engage the segment wall with the mounting body 508. For example, the body wall 512 can include one or more annular grooves 530 that extend radially into the body wall and into which portions (not numbered) of the segment wall 510 flow during the injection molding process. It should be understood that the grooves 530 are merely exemplary and that other combinations of structural features, such as, for example, annular protrusions or knurled surface treatments, can be used instead. Additionally or alternatively, an edge recess 532 can be included on or along the flange wall portion 526 (such as, for example, along the peripheral edge 528). If included, portions 534 of the segment wall 510 can flow around the flange wall portion 526 and into the edge recess 532 to at least partially wrap around the peripheral edge 528 of the mounting body.

[0059] The segment wall 510 may include an end wall portion 536 oriented transverse to the longitudinal axis AX and extending along one or more sides of the flange wall portion 526. The end wall portion 536 may extend peripherally toward an outer sidewall portion (or peripheral wall portion) 538, which extends axially from and along the end wall portion 536 toward a distal edge 540. The segment wall 510 may also include an inner sidewall portion 542, which is spaced apart from the outer sidewall portion 538 at an inner peripheral side thereof and extends axially from and along the end wall portion 536 toward a distal edge 544. The end member segment 500 may include a chamber portion 546, which is at least partially defined by the segment wall 510 between the outer sidewall portion 538 and the inner sidewall portion 542, and at least partially defines an end member chamber EMC. In the assembled state of the end member assembly EM1, the chamber portion 546 can be arranged to be in fluid communication with the chamber portion 418 of the end member segment 400 to substantially completely define the end member chamber EMC. In some cases, one or more connector wall portions 548 can extend between the outer side wall portion 538 and the inner side wall portion 542 and operatively connect the outer side wall portion and the inner side wall portion. If included, multiple connector wall portions 548 can be circumferentially spaced from each other around the longitudinal axis AX.

[0060] Optionally, the segment wall 510 may also include a mounting wall portion 550 that extends axially from and along the end wall portion 518 of the mounting body 508 toward a distal end 552 that is disposed toward the end 506 of the end member segment. The mounting wall portion 550 may be spaced apart from the inner sidewall portion 542 on an inner circumferential side thereof to at least partially define a bumper mounting recess 554 that is sized to at least partially receive and retain a jounce bumper 260 on or along the end member segment 500. In some cases, one or more connector wall portions 556 may extend between and operatively connect the inner sidewall portion 542 and the mounting wall portion 550. If included, a plurality of connector wall portions 556 may be circumferentially spaced apart from one another about the longitudinal axis AX.

[0061] like Figure 7 and Figures 9 to 14As shown, the outer sidewall portion 538 includes an end surface portion 558 disposed along a distal edge 540, which is oriented transversely to the longitudinal axis AX. The end surface portion 558 extends radially outward to a peripheral edge surface portion 560. The segment wall 510 also includes a protruding wall portion 562, which extends axially outward from and along the end surface portion 558 in a direction toward the distal edge 564. In some cases, the protruding wall portion 562 extends circumferentially around the end member segment 500, and is spaced apart from the peripheral edge surface portion 560 on the inner peripheral side thereof, so that at least some of the end surface portions 558 (identified by reference numeral 558A) are disposed on the inner peripheral side of the protruding wall portion 562, and some of the end surface portions 558 (identified by reference numeral 558B) are disposed on the outer peripheral side of the protruding wall portion.

[0062] The outer side wall portion 538 also includes an end surface portion 566 that is offset from the end 504 of the end member segment in the axial direction. The end surface portion 566 is oriented transversely to the longitudinal axis AX and can be arranged to be offset and aligned with the end surface portion 558 so that the inner peripheral edge surface portion (or inner peripheral side surface portion) 568 is formed on the inner peripheral side of the outer peripheral edge surface portion 560. In some cases, an alignment or assembly structure can be included on or along the end member segment 500, such as a corresponding alignment or assembly structure that can be adapted to positively engage with the end member segment 400. Figure 4 , Figure 7 and Figures 9 to 14 In the exemplary arrangement shown, the segment wall 510 may optionally include a groove or recess 570 extending axially inwardly into the segment wall from and along the end surface portion 566. If included, the groove or recess 570 may extend circumferentially around the end member segment 500, spaced from the inner peripheral edge surface portion 568 on the inner peripheral side thereof, such that at least some of the end surface portion 558 is disposed on the outer peripheral side of the groove or recess 570. In a preferred arrangement, the groove or recess 570 is also spaced from the protruding wall portion 562 on the inner peripheral side thereof, and is generally aligned with the protruding wall portion 444, such that in the assembled state, the protruding wall portion 444 and the groove 566 are axially coextensive.

[0063] In a preferred arrangement, the segment wall 510 of the end member segment 500 can be formed in an injection mold (such as in Fig. 9406 and 510 may be formed from a common polymeric material.

[0064] As discussed above, the end member segment 600 of the end member assembly EM1 is formed by in-situ injection molding or otherwise formed of a polymeric material together with the end member segment 400 and the end member segment 500. The end member segment 600 includes a segment wall 602 having an end surface portion 604 disposed to be in abutment with the end surface portion 436 and an end surface portion 606 disposed to be in abutment with the end surface portion 558. In addition, the segment wall 604 also includes an inner peripheral surface portion 608 disposed to be in abutment with the inner peripheral edge surface portion 568, so that the wall portion 610 and the wall portion 612 are disposed on the inner peripheral side of the protruding wall portion 444 and the protruding wall portion 562, respectively, and are coextensive therewith. The segment wall 602 also includes an outer peripheral surface portion 614, which faces the outer peripheral side in a direction away from the inner peripheral edge surface portion 568. In some cases, peripheral surface portion 614 may extend between and operatively connect peripheral edge surface portion 438 and peripheral edge surface portion 560. However, it should be appreciated that other configurations and / or arrangements may alternatively be used without departing from the subject matter of the present disclosure.

[0065] In a preferred arrangement, the segment wall 602 of the end member segment 600 may be formed at least in part from the segment wall 406 of the end member segment 400, the segment wall 510 of the end member segment 500, and an injection mold (such as in Figures 11 to 13 The segment wall 602 is manufactured or otherwise formed within a cavity (not numbered) defined by a surface (represented by dashed line MDC and mold surface SRF in FIG. 1 ). In addition, it should be understood that the segment wall 602 can be molded from any suitable polymeric material or combination of polymeric materials, such as, for example, fiber-reinforced polypropylene, fiber-reinforced polyamide, or unreinforced (i.e., relatively high-strength) thermoplastics (e.g., polyester, polyethylene, polyamide, polyether, or any combination thereof). In a preferred arrangement, the segment wall 602 can be formed from a common polymeric material with the segment wall 406 and / or the segment wall 510.

[0066] As discussed above, it should be understood that the segment walls of the end member segments 400, 500, and 600 can be molded from any suitable polymeric material or combination of polymeric materials. In some cases, each of the segment walls 406, 510, and 602 can be molded from a common, substantially identical polymeric material. In other cases, each of the segment walls 406, 510, and 602 can be molded from a common polymeric material, while one or more of the segment walls are molded from a different grade of other common polymeric material. As a non-limiting example, the segment walls 406 and 510 can be molded from a nylon polymer with 40% glass filling, and the segment wall 602 is molded from the same nylon polymer but with 10% glass filling. As another non-limiting example, segment wall 406 may be molded from nylon 6 / 6, while segment wall 510 and segment wall 602 are molded from nylon 6. In other cases, each of segment wall 406, segment wall 510, and segment wall 602 may be molded from different polymeric materials and / or different grades of polymeric materials. As a non-limiting example, segment wall 406 may be molded from nylon 6 / 6 with 40% glass filling, segment wall 510 may be molded from unfilled nylon 6, and segment wall 602 may be molded from an acetal homopolymer or copolymer. As another non-limiting example, segment wall 406 may be molded from nylon 6 / 6 with 40% glass filling, segment wall 510 may be molded from an ABS polymer, and segment wall 602 may be molded from a TPE polymer. Therefore, it should be recognized and understood that any suitable combination of materials may be used without limitation to the foregoing examples.

[0067] Reference now Figures 9 to 14 , shows and describes an example of a method of manufacturing an end member assembly (e.g., end member assembly EM1) according to the subject matter of the present disclosure. As indicated above, Fig. 9 An end member segment 400 is shown manufactured or otherwise formed in a cavity (not numbered) of an injection mold MDA having a mold segment MA1 and a mold segment MA2. Fig. 9 An end member segment 500 is shown manufactured or otherwise formed in a cavity (not numbered) of an injection mold MDB having a mold segment MB1 and a mold segment MB2. Fig.10, an injection mold MDA and an injection mold MDB are shown, wherein mold segments MA1 and mold segments MB1 are removed, respectively, so that ends 404 and ends 506 of end member segments 400 and 500 are at least partially exposed. It should be understood that in this case, end member segments 400 and 500 are still at least partially disposed in and supported by the corresponding cavities of injection molds MDA and MDB. In this regard, handling or manual operation of individual end member segments is avoided during the manufacturing process.

[0068] Fig.11 Shown as Fig.10 The corresponding mold segments MA2 and MB2 of the injection mold MDA and the injection mold MDB are put together as shown by the arrow MVT in FIG. 4 , so that the end member segment 400 and the end member segment 500 are adjacent to each other to at least partially form a groove or cavity CVT extending circumferentially around the end member segment. In some cases, the end member segment 400 and the end member segment 500 can be positioned to be adjacent to each other so that the protruding wall portion 444 and the groove or recess 570 are axially coextensive and adjacent to each other. In addition, the end member segment 400 and the end member segment 500 can be positioned to be adjacent to each other so that the end surface portion 436 and the end surface portion 566 of the end member segment are adjacent to each other. In this way, the adjacent engagement of the end member segment 400 and the end member segment 500 can at least partially define the inner peripheral extension of the cavity CVT.

[0069] Injection mold MDC may be introduced into injection mold MDA and / or injection mold MDB such that mold surface SRF together with at least end surface portion 436 of segment wall 406, end surface portion 558 of segment wall 510, and inner peripheral edge surface portion 568 of segment wall 510 at least partially defines cavity CVT. In some cases, distal edge 446 of protruding wall portion 444 and distal edge 564 of protruding wall portion 562 may be in abutment with end member segment 400 and end member segment 500 (such as, for example, Fig.12 and Fig.13 In such cases, the flow channel FCH can be formed between the distal edge 446 and the distal edge 564, which can help the injection molding polymer material flow toward the inner peripheral side of the protruding wall portion to form the wall portion 610 and the wall portion 612 of the segment wall 602. Fig.14 As shown, end member segment 600 secures end member segment 400 and end member segment 500 together and also forms a substantially fluid-tight connection between end member segment 400 and end member segment 500 when the cavity CVT is injected with a polymeric material.

[0070] 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.

[0071] 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, one-component and / or two-component epoxy resins.

[0072] 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.

[0073] 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 "means for..." or "step for..." are expressly used in a particular claim.

[0074] 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 having a longitudinal axis and dimensioned to be secured to an associated flexible spring member, the end member assembly comprising: a first end member segment having a first segment wall including a first peripheral wall portion; and, a second end member segment having a second segment wall including a second peripheral wall portion, the second end member segment being positioned in abutting engagement with the first end member segment such that the groove extends circumferentially around the first and second end member segments between the first and second peripheral wall portions; and, and a third end member segment having a third segment wall, the third end member segment being injection molded in situ with the first end member segment and the second end member segment so that the third end member segment extends circumferentially around the first end member segment and the second end member segment within the groove, wherein the third end member segment secures the first end member segment and the second end member segment together and also forms a fluid-tight seal therebetween.

2. The end member assembly of claim 1, wherein the first segment wall is injection molded from a first amount of polymeric material and the second segment wall is injection molded from a second amount of polymeric material.

3. The end member assembly of claim 2, wherein the third segment wall is injection molded in-situ with the first end member segment and the second end member segment from a third amount of polymeric material.

4. The end member assembly of claim 1, wherein the first segment wall includes a first end surface portion, the first end surface portion being oriented transverse to the longitudinal axis, the first end surface portion at least partially defining the groove. 5 . The end member assembly according to claim 4 , wherein the first outer peripheral wall portion includes a first outermost peripheral edge, and the first end surface portion extends from and along the first outermost peripheral edge toward the inner peripheral side.

6. The end member assembly of claim 4, wherein the first segment wall includes a first annular protrusion extending axially from and along the first end surface portion toward a first distal edge disposed within the groove.

7. The end member assembly of claim 6, wherein at least a portion of the third end member segment is disposed on an inner peripheral side of the first annular protrusion and is coextensive therewith.

8. The end member assembly of claim 6, wherein at least a portion of the third end member segment is disposed on an outer peripheral side of the first annular protrusion and is coextensive therewith.

9. The end member assembly of any one of claims 1 to 8, wherein the second segment wall includes a second end surface portion, the second end surface portion being oriented transverse to the longitudinal axis, the second end surface portion at least partially defining the groove. 10 . The end member assembly according to claim 9 , wherein the second outer peripheral wall portion includes a second outermost peripheral edge, and the second end surface portion extends from and along the second outermost peripheral edge toward the inner peripheral side.

11. The end member assembly of claim 9, wherein the second segment wall includes a second annular protrusion extending axially from and along the second end surface portion toward a second distal edge disposed within the groove.

12. The end member assembly of claim 11, wherein at least a portion of the third end member segment is disposed on an inner peripheral side of the second annular protrusion and is coextensive therewith.

13. The end member assembly of claim 11, wherein at least a portion of the third end member segment is disposed on an outer peripheral side of the second annular protrusion and is coextensive therewith.

14. The end member assembly according to any one of claims 1 to 8, wherein the first segment wall includes a side surface portion extending around the first end member segment along the first peripheral wall portion, wherein the side surface portion at least partially defines an inner peripheral side extent of the groove.

15. The end member assembly of claim 14, wherein the third end member segment is disposed in abutting engagement with the side surface portion of the first segment wall.

16. An end member assembly according to any one of claims 1 to 8, wherein the first segment wall includes a first distal surface portion, the first distal surface portion is oriented transversely to the longitudinal axis, and the second segment wall includes a second distal surface portion, the second distal surface portion is oriented transversely to the longitudinal axis and faces the first distal surface portion.

17. The end member assembly of claim 16, wherein the first distal surface portion and the second distal surface portion are configured to be in abutting engagement with each other.

18. An end member assembly according to claim 16, wherein the first segment wall includes an alignment groove, which extends axially from and along the first distal surface into the first peripheral wall portion, and the second segment wall includes an alignment protrusion, which extends axially outward from and along the second distal surface, wherein the alignment protrusion is at least partially received in the alignment groove.

19. The end member assembly of any one of claims 1 to 8, wherein the first end member segment and the second end member segment at least partially define an end member chamber within the end member assembly.

20. The end member assembly of any one of claims 1 to 8, wherein the second segment wall of the second end member segment includes an outer sidewall portion dimensioned to receivingly engage the associated flexible spring member.

21. The end member assembly of claim 20, further comprising an annular ring at least partially embedded in the outer sidewall portion of the second segment wall.

22. The end member assembly of claim 21, wherein the annular ring is an endless annular ring formed at least in part from a metallic material.

23. The end member assembly of any one of claims 1 to 8, further comprising a mounting insert at least partially embedded in the first segment wall of the first end member segment.

24. A gas spring assembly, comprising: a flexible spring member extending circumferentially about a longitudinal axis and extending longitudinally between opposing first and second ends such that a spring chamber is at least partially defined between the first and second ends; an end member fixed to the first end of the flexible spring member; and, 24. An end member assembly according to any one of claims 1 to 23, said end member assembly being operatively secured to said second end of said flexible spring member such that a fluid-tight connection is formed therebetween.

25. A gas spring and damper assembly, the gas spring and damper assembly comprising: A damper assembly having a longitudinally extending axis and comprising: a damper housing including a housing wall extending axially between opposing first and second ends, the housing wall at least partially defining a damping chamber containing a volume of damping fluid; and, a damper rod assembly including an elongated damper rod and a damper piston fixed along the elongated damper rod, the damper rod assembly being operatively interengaged with the damper housing for reciprocal displacement relative to the damper housing, wherein the damper piston is disposed within the damping chamber and at least a portion of the elongated damper rod projects axially outwardly from the first end of the damper housing; and, The gas spring assembly of claim 24, wherein the gas spring assembly is disposed axially coextensive with at least a portion of the damper assembly.

26. The gas spring and damper assembly of claim 25, wherein the end member is operatively secured to the damper housing and the end member assembly is operatively connected to the elongated damper rod.

27. A suspension system, comprising: A compressed gas system, the compressed gas system comprising a compressed gas source and a control device; as well as, At least one gas spring assembly according to claim 24, wherein the at least one gas spring assembly is configured to be in fluid communication with the compressed gas source through the control device so that compressed gas can be selectively transmitted into and out of at least the spring chamber, or at least one gas spring and damper assembly according to claim 25 or 26, wherein the gas spring assembly of the gas spring and damper assembly is configured to be in fluid communication with the compressed gas source through the control device so that compressed gas can be selectively transmitted into and out of at least the spring chamber.

28. A method of manufacturing an end member assembly, the method comprising: injecting a first quantity of polymeric material into a first mold cavity at least partially defined by a first mold section and a second mold section to mold a first end member section; injecting a second amount of polymeric material into a second mold cavity at least partially defined by the first second mold segment and the second second mold segment to mold a second end member segment separate from the first end member segment; separating the first first mold section from the second first mold section thereby exposing a portion of the first end member section while the first end member section remains in place within the first mold cavity of the second first mold section; separating the first second mold section from the second second mold section thereby exposing a portion of the second end member section while the second end member section remains in place within the second mold cavity of the second second mold section; introducing the first end member segment in situ in the second first mold segment into the second end member segment in situ in the second second mold segment, thereby forming a groove extending circumferentially around the first end member segment and the second end member segment; as well as, A third amount of polymeric material is injected in situ into the groove between the first and second end member segments to form a third end member segment that operatively connects the first and second end member segments to form a fluid-tight joint therebetween.

29. The method of claim 28, wherein injecting the first amount and the second amount of polymeric material comprises injecting a common type of polymeric material.

30. The method of any one of claims 28 and 29, wherein injecting the third amount of polymeric material comprises injecting a common type of polymeric material as at least one of the first amount and the second amount of polymeric material.

31. The method of any one of claims 28 and 29, further comprising providing a mounting insert, and wherein injecting the first amount of polymeric material comprises overmolding at least a portion of the mounting insert.

32. The method of any one of claims 28 and 29, further comprising providing an annular ring, and wherein injecting the second amount of polymeric material comprises overmolding at least a portion of the annular ring.

33. The method according to any one of claims 28 and 29, further comprising providing at least one third mold segment, and operatively joining the at least one third mold segment to one or more of the first first mold segment, the second first mold segment, the first second mold segment and / or the second second mold segment to at least partially define the third mold cavity within the groove before injecting the third amount of polymeric material into the third mold cavity.

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