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

Abstract

The end member assembly includes a first end member and a second end member. The first end member includes a first end member wall having a first side wall portion and a first flange wall portion. The first flange wall portion includes a plurality of attachment channels extending therethrough. The second end member includes a second end member wall having a second side wall portion and a second flange wall portion. The second end member includes an attachment stud disposed along the second flange wall portion. The first end member and the second end member are positioned to be axially coextensive with each other, wherein the attachment studs extend through corresponding attachment channels. The stud heads are integrally formed along the attachment studs, wherein the stud heads are adjacently engaged with the first flange wall portion, thereby maintaining the first end member and the second end member in an assembled state.

Description

Background Art

[0001] The subject matter of the present disclosure relates broadly to gas spring devices and, more particularly, to end member assemblies for gas spring and damper assemblies. The end member assemblies may include two or more end member components assembled in an axially fixed relationship to each other. Also included are gas spring and damper assemblies including one or more such end member assemblies, 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 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, multiple spring arrangements are used to accommodate the forces and loads associated with the operation and use of the vehicle. In some cases, the multiple spring arrangements may take the form of a gas spring assembly that utilizes compressed gas as the working medium. Gas spring assemblies of various types, kinds, and configurations are well known and commonly used. A typical gas spring assembly may include a flexible spring member secured between relatively rigid end members and / or end member assemblies. The end members and / or end member assemblies are securely secured to the flexible spring member (e.g., a convoluted bellows or an elongated flexible sleeve) such that a substantially fluid-tight spring chamber is formed within the gas spring assembly.

[0005] A plurality of damping devices are operable to dissipate energy associated with undesired inputs and movements of a sprung mass, such as, for example, road surface inputs occurring under dynamic operation of a vehicle. Typically, such dampers are liquid filled and are operably connected between a sprung mass and an unsprung mass, such as, for example, a body and an axle of a vehicle. An example of such a damping component is a conventional shock absorber commonly used in vehicle suspension systems. Independent of the type and / or kind of working medium used in the damping device, one of the damping devices may in some cases be coextensively engaged with a corresponding one of the gas springs to form a so-called gas spring and damper assembly.

[0006] 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

[0007] An example of an end member assembly according to the subject matter of the present disclosure may have a longitudinal axis and may be sized to be fixed to an associated flexible spring member. The end member assembly may include a first end member and a second end member. The first end member may include a first end member wall, which may include a first side wall portion extending circumferentially around the longitudinal axis and a first flange wall portion extending radially outward from the first side wall portion. The first flange wall portion may include a first flange surface portion and a second flange surface portion facing opposite to the first flange surface portion. The first flange wall portion may include a plurality of attachment channels extending through the first flange wall portion and arranged in a circumferentially spaced relationship with each other around the longitudinal axis. The second end member may include a second end member wall, which has a second side wall portion extending circumferentially around the longitudinal axis and a second flange wall portion extending radially outward from the second side wall portion. The second flange wall portion may include a first second flange surface portion. The second end member may include a plurality of attachment studs arranged along the second flange wall portion in a circumferentially spaced relationship with each other around the longitudinal axis. The plurality of attachment studs may protrude axially from the first second flange surface portion. The first end member and the second end member may be positioned axially coextensive with each other such that the first first flange surface portion and the second first flange surface portion are disposed in a facing relationship with each other. At least one of the plurality of attachment studs may extend through a corresponding one of the plurality of attachment channels and beyond the second first flange surface portion. A stud head may be integrally formed along at least one of the plurality of attachment studs, wherein the stud head abuts against the second first flange surface portion of the first flange wall portion, thereby retaining the first end member and the second end member in an assembled state.

[0008] 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 operably 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 the preceding paragraph can be operably connected to the elongated damper rod and operably fixed to the first end of the flexible spring member so that a substantially fluid-tight connection is formed therebetween. The second end member assembly can be supported on the damper housing and operably fixed to the second end of the flexible spring member so that a substantially fluid-tight connection is formed therebetween.

[0009] 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 delivered into and out of the spring chamber.

[0010] One example of a method according to the subject matter of the present disclosure includes manufacturing an end member assembly that is sized to be fixed to an associated flexible spring member. The method may include providing a first end member having a first end member wall. The first end member wall may include a first side wall portion extending circumferentially around a longitudinal axis and a first flange wall portion extending radially outward from the first side wall portion. The first flange wall portion may include a first flange surface portion and a second flange surface portion facing opposite to the first flange surface portion. The first flange wall portion may include a plurality of attachment channels extending through the first flange wall portion and arranged in a circumferentially spaced relationship with each other around the longitudinal axis. The method also includes providing a second end member having a second end member wall. The second end member wall includes a second side wall portion extending circumferentially around the longitudinal axis and a second flange wall portion extending radially outward from the second side wall portion. The second flange wall portion may include a first second flange surface portion. The second end member may also include a plurality of attachment studs arranged along the second flange wall portion in a circumferentially spaced relationship with each other around the longitudinal axis. The plurality of attachment studs may protrude axially from the first second flange surface portion. The method also includes positioning the first end member and the second end member to be axially coextensive with each other so that the first first flange surface portion and the second first flange surface portion are disposed in a facing relationship with each other. In this arrangement, at least one of the plurality of attachment studs extends through a corresponding one of the plurality of attachment channels and beyond the second first flange surface portion. The method also includes integrally forming a stud head along at least one of the plurality of attachment studs opposite the second flange wall portion so that the stud head abuts against the second first flange surface portion of the first flange wall portion, thereby retaining the first end member and the second end member in an assembled state. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] 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.

[0012] Figure 2 is a top perspective view of one example of a gas spring and damper assembly in accordance with the disclosed subject matter.

[0013] Figure 3 yes Figure 2 Side elevation view of the gas spring and damper assembly in FIG.

[0014] Figure 4 yes Figure 2 and Figure 3 Top plan view of the gas spring and damper assembly.

[0015] Figure 5 It is along Figure 4The line 5-5 in Figures 2 to 4 Cross-sectional side view of the gas spring and damper assembly.

[0016] Figure 6 yes Figures 2 to 5 Gas spring and damper components in Figure 5 An enlarged view of the portion marked as detail 6.

[0017] Figure 7 yes Figures 2 to 6 Gas spring and damper components in Figure 5 An enlarged view of the portion marked as detail 7.

[0018] Figure 8 Before performing the permanent assembly process according to the subject matter of the present disclosure Figure 7 An enlarged view of a portion of the gas spring and damper assembly.

[0019] Fig. 9 Before the permanent assembly process Figures 2 to 8 An exploded view of an end member assembly according to the disclosed subject matter is shown. DETAILED DESCRIPTION

[0020] 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.

[0021] 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.

[0022] 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.

[0023] 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).

[0024] 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.

[0025] 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.

[0026] 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 relating 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 a wheel or tire or other component 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.

[0027] 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 9 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 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 an axially coextensive arrangement with respect to one another and may be operably secured to one another in any suitable manner, such as, for example, as described below. Figure 5 and Figure 6 As shown, a longitudinal axis AX extends longitudinally along the assembly AS1.

[0028] 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.

[0029] 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.

[0030] 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.

[0031] 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.

[0032] It will be appreciated that the gas spring and damper assembly AS1 may be operably 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 operably connected to the associated sprung mass, while the other end of the assembly is disposed toward and operably 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 The gas spring and damper assembly AS1 may be operably engaged (directly or indirectly) with the associated vehicle body BDY in the housing and may be secured to the component 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 are operably 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 a lower structural component LSC ( Figure 3 ) (such as Figure 1The device may be fixed on or along the relevant suspension component SCP in the embodiment and may be fixed thereto in any suitable manner.

[0033] The gas spring assembly GS1 may include a flexible spring member 300 that may extend circumferentially about an axis AX and may be secured 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 (or end member body) 400 to which one end of the flexible spring member 300 may be secured and an end member (or end member body) 500 to which the end 212 of the damper rod assembly 202 is operably connected. Additionally, 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 secured on or along the end member assembly 600 in any suitable manner. Additionally, it should be understood that the end member 600 can be operably supported on or along the damper housing 200 in a suitable manner. As a non-limiting example, the damper housing 200 can include a support wall or support wall portion 234 extending radially outward from along the damper housing toward the peripheral edge 236, wherein the end member assembly 600 is at least partially supported on or along the support wall portion 234.

[0034] 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 8 304, 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 can be used.

[0035] 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.

[0036] 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 (not identified) 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.

[0037] 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 operably connected to the associated sprung mass, while another component is arranged toward and operably connected to the associated unsprung mass. For example, Figures 2 to 8 As shown, the end member 500 may include one or more fixing devices 502 (e.g., threaded fasteners) operable to fix 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.

[0038] For example, the damper assembly DP1 and / or the end member assembly EM1 may include a bushing assembly 238, which may be supported on or along the end member 500, and to which the damper rod assembly 202 is operably connected. Additionally or in the alternative, the damper assembly DP1 and / or the end member assembly EM1 may include a bushing assembly 240, which may be supported on or along the end member 500, and to which the damper rod assembly 202 is operably connected. If included, the bushing assembly 238 may include an inner metal 242, an outer metal 244, and an elastomer 246 permanently attached between the inner metal and the outer metal (i.e., not separable without damaging, destroying, or materially changing at least one of the component parts). Additionally or in the alternative, if included, the bushing assembly 240 may include an inner metal 248, an outer metal 250, and an elastomer 252 permanently attached between the inner metal and the outer metal. In this arrangement, the elongated damper rod 218 may extend through the damper bushing 238 and / or the damper bushing 240 and may be secured there along in a suitable manner, for example, by matingly engaging a securing device 254 (e.g., a nut) with the connecting structure 230 of the elongated damper rod 216.

[0039] In some cases, inner metal 242 may take the shape of an annular plate or disk that protrudes radially outward from inner peripheral edge 256 toward outer peripheral edge 258, with at least a portion of inner metal 242 embedded within elastomer 246. Figure 5 and Figure 6In the assembled state of the exemplary arrangement shown, the inner metal 248 can be located on or toward a step or shoulder surface portion 260 formed on or along the elongated damper rod 216 toward its end 212. The inner metal 242 can be located on, along, or otherwise adjacent to an end 262 of the inner metal 248, with a spacer 264 (which is optional, depending on the geometry of the inner metal 242) disposed on, along, or otherwise adjacent to the inner metal end of the inner metal 242 opposite the inner metal 248. If included, a washer 266 can optionally be disposed on or along the spacer 264, wherein the fixing device 254 has two inner metals facing the shoulder surface portion 260 (if included, through the spacer and / or the washer) to at least partially fix the elongated damper rod 216 to or along the end member assembly EM1 through the bushing assembly 238 and / or the bushing assembly 240. One or more sealing devices 268 can be operably disposed between the elongated damper rod 216 and the inner metal 242 and / or the inner metal 248 so that a substantially fluid-tight seal is formed therebetween.

[0040] 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 270 positioned on or along the elongated damper rod 216 within the spring cavity 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 the full jounce state of the assembly AS1. However, it should be understood that other constructions and / or arrangements may be used alternatively.

[0041] 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 602, which is arranged along the damper housing 200 and supported on the damper housing. The end member housing (or housing segment) 604 is supported on the end member core and may include an outer surface 606, 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 602 may be configured to receive and support one or more end member housings and / or housing segments, such as any one of a plurality of different sizes, shapes and / or configurations (e.g., outer profiles with different profiles and / or shape combinations).

[0042] 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 602 and / or the end member shell segment 604 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).

[0043] The end member core 602 is shown as extending circumferentially about the axis AX and extending longitudinally between opposite ends 608 and an end 610. The end member core 602 can include a first or upper mounting section 612 toward the end 608, to which or along which the end 308 of the flexible spring member 300 can be operably connected 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 612 of the end member core 602. 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.

[0044] The end member core 602 may be supported on or along the damper housing 200 in any suitable manner. As a non-limiting example, an end surface portion 614 of the end member core 602 along its end 610 may be disposed on or along a support wall portion 234 of the damper housing 200 to support the end member core on the damper housing in at least one axial direction. A sealing device 616 may be sealingly disposed between the end member core 602 and the damper housing 200 such that a substantially fluid-tight seal is formed therebetween. However, it should be understood that other configurations and / or arrangements may alternatively be used.

[0045] As described above, the end member assembly EM1 can be 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 operably connect the gas spring assembly and the damper assembly to related structural components, such as, for example, the upper structural component USC. The end member (or end member body) 400 and the end member (or end member body) 500 can be permanently interconnected in a substantially fixed coextensive arrangement by using one or more attachment studs fixed or otherwise arranged on or along any one or both of the end members. One or more attachment studs extend axially through one or more attachment channels in the other or both end members. The distal end of the attachment stud is permanently deformed into an attachment head having a cross-sectional size larger than the cross-sectional size of the attachment channel. The end members 400 and 500 are permanently fixed relative to each other in a substantially fixed axial position (i.e., cannot be changed without damage, destruction or material change).

[0046] In the arrangement shown and described herein, end member 400 includes one or more attachment studs and end member 500 includes one or more attachment channels. However, it should be understood that alternative configurations in which end member 400 includes one or more attachment channels and end member 500 includes one or more studs are intended to find support in the present disclosure, as if these embodiments are fully shown and described herein. Additionally, or in the alternative, alternative configurations in which end member 400 and end member 500 each include one or more attachment studs and one or more attachment openings that cooperate with each other are also intended to find full support in the present disclosure, as if these embodiments are fully shown and described herein.

[0047] The end member 400 is shown and described herein as including an end member wall 402 extending circumferentially around a longitudinal axis AX. The end member wall 402 includes a side wall portion 404 having an inner surface portion 406 facing radially inward. The side wall portion 404 may include an outer surface portion 408 sized to receive the end 306 of the flexible spring member so as to be secured thereto in a suitable manner, such as, for example, by a crimp ring 314. In some cases, the end member wall 402 may include a side wall portion 410 disposed radially inward of the side wall portion 404 so that an annular groove or channel 412 may be disposed therebetween. The end member wall 402 at least partially defines an end member channel 414 that extends through the end member 400 and is sized to receive at least a portion of the end member 500. Thus, if included, sidewall portion 404 and / or sidewall portion 410 can at least partially define an inner surface portion 416 of end member wall 402, on or along which a corresponding outer surface portion of end member 500 can be located, as described below.

[0048] In some cases, a backing ring 418 can be disposed radially inwardly of the sidewall portion 404 to provide additional strength and / or rigidity to the end member 400, for example, under the crimping load or force applied by the crimp ring 314. The flange wall portion 420 is disposed transverse to the longitudinal axis AX and can extend radially outward beyond the sidewall portion 404 to a peripheral edge 422. In some cases, if included, the flange wall portion 420 can also extend radially inwardly and operably connect the sidewall portion 404 and the sidewall portion 410, for example, and can at least partially define a closed end of the channel 412. The flange wall portion 420 of the end member wall 402 includes a flange surface portion 424 from which at least the sidewall portion 404 extends toward a distal edge 426. The flange wall portion 420 also includes a flange surface portion 428 facing opposite the flange surface portion 424.

[0049] With reference to the above discussion of alternative configurations included herein and as an example of an end member assembly according to the subject matter of the present disclosure, the end member 400 may include one or more attachment studs 430 operably connected to the end member wall 402. In a preferred configuration, a plurality of attachment studs 430 are provided in a circumferentially spaced relationship with each other around the longitudinal axis AX. The attachment studs 430 may extend from the flange surface portion 428 axially along the flange wall portion 420 toward the distal end 432. In some cases, the attachment studs 430 may be integrally attached to the end member wall 402, for example, on or along its flange wall portion 420. However, in a preferred arrangement, the attachment studs 430 may be integrally formed with the end member wall 402, for example, on or along the flange wall portion 420. In some cases, the attachment studs 430 may include one or more holes 434 extending from the distal end 432 along the attachment studs into the attachment studs, for example, which may help form an attachment joint during assembly. Attachment stud 430 at Fig. 9 430 is shown as having an overall length extending from at least approximately the flange surface portion 428 to at least approximately the distal end 432 prior to assembly, as indicated by reference dimension LG1. After assembly, as described below, the attachment stud 430 is permanently deformed and has an overall length extending from at least approximately the flange surface portion 428 to the distal extent of the stud head (or attachment head) 430', as indicated by reference dimension LG2. In addition, the attachment stud 430 is also shown as having an overall length extending from at least approximately the flange surface portion 428 to the distal extent of the stud head (or attachment head) 430' prior to assembly, as indicated by reference dimension LG2. Fig. 9 and after being permanently deformed during assembly with the stud head 430 formed integrally with the attachment stud 430, has a cross-sectional dimension of Figure 7 The cross-sectional dimension represented by reference dimension CD2.

[0050] The end member 500 is shown and described herein as including an end member wall 504 extending circumferentially around a longitudinal axis AX. The end member wall 504 includes a side wall portion 506 extending axially from an end surface portion 508 toward an end surface portion 510 facing opposite to the end surface portion 508. The side wall portion 506 may include an inner side surface portion 512 and an outer side surface portion 514. The end member wall 504 may also include a side wall portion 516 disposed radially inwardly of the side wall portion 506 so that an annular groove or channel 518 may be disposed therebetween. The side wall portion 516 may include an inner side surface portion 520 facing radially inwardly.

[0051] End member wall 504 also includes a flange wall portion 522 extending outwardly from side wall portion 506 to an outer peripheral edge 524. End wall portion 526 extends radially inward from side wall portion 506. End wall portion 526 can be operably connected to side wall portions 506 and 516 and together therewith can at least partially define a recess 528 in which bushing assembly 238 and / or 240 is at least partially received and a recess 530 in which at least a portion of jounce bumper 270 is at least partially received. End wall portion 526 can extend radially inward toward an inner peripheral edge 532 that at least partially defines an opening or passage 534 through end member 500. Additionally, seal 536 can be disposed between end members 400 and 500, and it should be appreciated that any suitable configuration and / or arrangement can be used to receive and retain seal 536 in sealing engagement between the end members such that a substantially fluid-tight seal is maintained therebetween. As a non-limiting example, annular groove 538 may be formed on or along outer side surface portion 514 of sidewall portion 506 that is sized to at least partially receive seal 536. However, it should be appreciated that other configurations and / or arrangements may alternatively be used.

[0052] As described above, the bushing assembly 238 and / or 240 can be at least partially disposed within the recess 528 of the end member 500 and can be operably secured thereto in any suitable manner. As a non-limiting example, if included, the bushing assembly 240 can be disposed within the recess 528, wherein the outer metal member 250 and / or the elastomer 252 are disposed on or along the end wall portion 526 such that the outer surface of the outer metal member 250 is disposed in a facing relationship with the inner surface portion 520 of the side wall portion 516. Additionally or in the alternative, the bushing assembly 238 can be disposed within the recess 528, wherein the outer metal member 244 is disposed in a facing relationship with the inner surface portion 512 of the side wall portion 506. In this case, one or more sealing devices 540 can be operably disposed between at least one of the outer metal members 244 and / or 250 and at least one of the side wall portions 506 and / or 516 such that a substantially fluid-tight seal is formed therebetween. Optionally, an annular washer or disk 542 can be supported on the sidewall portion 516 and / or end surface portions (not numbered) of the outer metal 250. If included, the outer metal 244 can be supported on or along the annular disk 542. Additionally, or in the alternative, the annular washer or disk 544 can be disposed within a recess 528 on or along the outer metal 244 and / or elastomer 246 of the bushing assembly 238. If included, the outer metal 244 and the outer metal 250 can be secured within the recess 528 in any suitable manner, such as by a retaining ring 546 operatively engaging a corresponding groove (not numbered) disposed along the inner side surface portion 512.

[0053] The flange wall portion 522 of the end member wall 504 includes a flange surface portion 548 facing the end surface portion 508 in the axial direction and a flange surface portion 550 facing opposite to the side surface portion 548. Therefore, the flange wall portion 522 has a thickness or height between the flange surface portions 548 and 550, such as Figure 7 denoted by reference dimension THK. In addition, with repeated reference to the above discussion regarding alternative configurations included herein and as an example of an end member assembly according to the subject matter of the present disclosure, the end member 500 may include one or more attachment channels 552 extending through the flange wall portion 522. In a preferred arrangement, a plurality of attachment channels 552 may be used. In such a case, the plurality of attachment channels may be disposed in a circumferentially spaced relationship to one another about the longitudinal axis AX. The attachment channels 552 have a plurality of attachment channels 552 extending therethrough. Fig. 9 Thus, the thickness THK of the flange wall portion 522 together with the total length LG1 of the attachment stud 430 before assembly and the total length LG2 of the attachment stud with the stud head 430 after assembly are represented by the following relationship:

[0054] LG1≥LG2>THK

[0055] In addition, the cross-sectional dimension CD3 of the attachment channel 552 together with the cross-sectional dimension CD1 of the attachment stud 430 and the cross-sectional dimension CD2 of the stud head 430 is represented by the following relationship:

[0056] CD2>CD3>CD1

[0057] As described above, the end member 500 can include a plurality of fixing devices 502 (e.g., threaded fasteners) operably connected to the end member wall 504, for example, on or along the flange wall portion 522. In the arrangement shown and described herein, the flange wall portion 522 includes a plurality of holes 554 extending therethrough, with one fixing device 502 disposed within a respective one of the holes 554. In some cases, the fixing device 502 can take the form of a threaded fastener including a fastener head 556 disposed on or along the flange surface portion 548 such that the fixing device extends through the hole 554 with the remainder of the threaded fastener protruding axially outward beyond the flange surface portion 550. In some cases, the flange wall portion 544 can include one or more recesses 556 formed therein along the flange surface portion 550, the recesses being sized to receive at least a portion of the fastener head 558.

[0058] In some cases, end member 400 may be at least partially formed of a first material (e.g., a metallic material), and end member 500 may be formed of a second material different from the first material (e.g., a polymer material or a combination of polymer materials). As non-limiting examples, the first material may be steel, aluminum, or zinc, and the second material may be, for example, fiber-reinforced polypropylene, fiber-reinforced polyamide, or an unreinforced (i.e., relatively high strength) thermoplastic material (e.g., polyester, polyethylene, polyamide, polyether, or any combination thereof).

[0059] In the assembled state, the end member 500 is at least partially received within the channel 414 of the end member 400 such that the flange surface portion 428 and the flange surface portion 550 are arranged in a facing relationship with each other. In addition, in this arrangement, each of the attachment studs 430 is aligned with, extends into and passes through a corresponding one of the attachment channels 552. In some cases, the flange surface portions 428 and 550 can be arranged to abut against each other, for example, as Figures 5 to 8As shown. The securing devices 502 are disposed in a circumferentially spaced relationship with each other and may include one or more securing devices 502 disposed between adjacent ones of the attachment studs 430 and / or between adjacent ones of the attachment channels 552. Once coextensively positioned with respect to each other, the end members 400 and 500 may be permanently secured together by permanently deforming the distal ends of the attachment studs 430 into attachment heads 430' integrally formed by the attachment studs 430. The stud heads 430' are configured to abut against the flange surface portions 426 and have a cross-sectional dimension that is larger than the cross-sectional dimension of the attachment channels, which permanently secures the end members 400 and 500 in a substantially fixed axial position relative to each other (i.e., not separable without damaging, destroying, or materially altering at least one of the component components).

[0060] One example of a method of assembling an end member assembly according to the subject matter of the present disclosure includes providing a first end member, for example, one of the end members 400 and 500. The method also includes providing a second end member, for example, the other of the end members 400 and 500. The method may also include at least approximately rotationally aligning one or more attachment studs 430 with corresponding attachment channels 552 about the longitudinal axis. The method may also include axially coextensively positioning the end members 400 and 500 so that one or more attachment studs 430 extend into and through the corresponding attachment channels 552. The method may also include permanently deforming the distal ends 432 of the attachment studs 430 to attachment heads 430' integrally formed by the attachment studs 430. The attachment heads 430' have a cross-sectional dimension that is larger than the cross-sectional dimension of the attachment channels, which fixes the end members 400 and 500 in a substantially fixed axial position relative to each other. As a non-limiting example, a suitable technique for permanently deforming the attachment stud 430 to include an integrally formed attachment head 430' is sometimes referred to as thermoplastic staking or heat staking, such as Figure 8 In the figure, it is represented by the device TPS.

[0061] 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, which include, but are 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 configurations. In this regard, the terms "circumferential", "circumferentially", etc. may be synonymous with terms such as "peripheral", "peripherally", etc.

[0062] 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.

[0063] 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.

[0064] 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.

[0065] 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, the first end member including a first end member wall formed at least in part from a first material, the first end member wall including a first side wall portion extending circumferentially about the longitudinal axis and a first flange wall portion extending radially outwardly from the first side wall portion, the first flange wall portion including a first first flange surface portion, a second first flange surface portion facing oppositely from the first first flange surface portion and sized to abuttingly engage along an associated vehicle structure, and a third first flange surface portion facing oppositely from the first first flange surface portion and axially offset from the second first flange surface portion, the first flange wall portion including a plurality of attachment channels extending therethrough, the plurality of attachment channels being disposed in circumferentially spaced relationship to one another about the longitudinal axis; a plurality of securing devices accessible along said second first flange surface portion and operable to secure said second first flange surface portion of said first flange wall portion in abutting engagement along an associated vehicle structure, said plurality of securing devices being disposed in circumferentially spaced relationship to one another about said longitudinal axis, one or more securing devices of said plurality of securing devices being disposed between adjacent ones of said plurality of attachment channels; a second end member, the second end member including a second end member wall formed at least in part from a second material different from the first material, the second end member wall including a second side wall portion extending circumferentially about the longitudinal axis, a third side wall portion disposed radially outward of the second side wall portion and sized to receivably engage an associated flexible spring member therealong, and a second flange wall portion extending radially outwardly from at least one of the second side wall portion and the third side wall portion, the second flange wall portion including a first second flange surface portion, the second end member including a plurality of attachment studs integrally formed from the second material by the second end member wall, the plurality of attachment studs being disposed along the second flange wall portion in circumferentially spaced relationship to one another about the longitudinal axis, the plurality of attachment studs projecting axially from the first second flange surface portion; as well as a sealing device, the sealing device being at least partially formed from a third material; the first end member and the second end member being positioned axially coextensive with each other, wherein the sealing means is sealingly disposed between axially coextensive portions of the first side wall portion of the first end member and the second side wall portion of the second end member and such that the first first flange surface portion and the second first flange surface portion are disposed in facing relationship with each other; and At least one of the plurality of attachment studs extends through a corresponding one of the plurality of attachment channels, wherein a stud head is integrally formed along the at least one of the plurality of attachment studs, the stud head is abuttingly engaged with the third first flange surface portion of the first flange wall portion, thereby maintaining the first end member and the second end member in an assembled state, and the stud head is axially disposed between the second first flange surface portion and the third first flange surface portion, so that the second first flange surface portion can be fixed in abutting engagement with an associated vehicle structure.

2. The end member assembly of claim 1 further comprising a plurality of circumferentially spaced receiving holes extending through the first flange wall portion of the first end member, wherein one of the plurality of fixing devices extends through one of the plurality of receiving holes.

3. The end member assembly of claim 2, wherein each of the plurality of receiving holes is circumferentially positioned between adjacent ones of the plurality of attachment channels and / or between adjacent ones of the plurality of attachment studs.

4. The end member assembly of claim 2 or 3, wherein a portion of each of the plurality of securing devices is axially captured between the first flange wall portion and the second flange wall portion.

5. An end member assembly according to claim 2 or 3, wherein at least one of the first first flange surface of the first flange wall portion and the first second flange surface portion of the second flange wall portion includes a plurality of recesses, wherein each of the plurality of recesses is sized to receive a portion of one of the plurality of fixing devices so that the plurality of fixing devices are axially captured between the first flange wall portion and the second flange wall portion.

6. The end member assembly of any one of claims 1 to 3, wherein an outer surface portion of the third side wall portion is dimensioned to receivably engage an associated flexible spring member for securing thereto.

7. An end member assembly according to any one of claims 1 to 3, wherein the first end member and the second end member are coextensively positioned so that the first first flange wall portion of the first end member and the first second flange wall portion of the second end member are arranged to abut each other.

8. An end member assembly according to any one of claims 1 to 3, wherein the third first flange surface portion of the first flange wall portion of the first end member wall is one of a plurality of third first flange surface portions arranged in circumferentially spaced relationship with each other around the longitudinal axis.

9. An end member assembly according to any one of claims 1 to 3, wherein the corresponding one of the plurality of attachment channels has a channel cross-sectional size, and the stud head of the at least one of the plurality of attachment studs has a head cross-sectional size that is larger than the channel cross-sectional size.

10. An end member assembly according to claim 9, wherein the channel cross-sectional dimensions of each of the plurality of attachment channels are substantially equal to each other, and each of the plurality of attachment studs includes a stud cross-sectional dimension, which is smaller than the channel cross-sectional dimension of the plurality of attachment channels, so that the plurality of attachment studs can each extend through a corresponding one of the plurality of attachment channels and engage cooperatively therewith.

11. An end member assembly according to any one of claims 1 to 3, wherein the first side wall portion of the first end member wall is arranged radially inwardly of the second side wall portion of the second end member wall, wherein the first side wall portion at least partially defines a recess extending axially through the first end member, the recess being sized to receive a portion of an associated damper assembly for operably connecting to the end member assembly.

12. The end member assembly of claim 11, further comprising a first bushing assembly at least partially disposed within the recess of the first end member and sized to operably connect the first end member with the associated damper assembly.

13. The end member assembly of claim 12, further comprising a second bushing assembly at least partially disposed within the recess of the first end member and sized to operably connect the first end member with the associated damper assembly.

14. The end member assembly of claim 13, further comprising a sealing device disposed between the first end member wall and one of the first bushing assembly and the second bushing assembly such that a substantially fluid-tight seal is formed therebetween.

15. An end member assembly according to any one of claims 1 to 3, wherein one of the first side wall portion of the first end member and the second side wall portion of the second end member includes an annular groove, wherein the sealing device is at least partially arranged in the groove between the first end member and the second end member.

16. 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 operably 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, A gas spring assembly, the gas spring assembly being arranged in an axially coextensive relationship with at least a portion of the damper assembly, the gas spring assembly comprising: a flexible spring member extending circumferentially about the longitudinally extending axis and extending longitudinally between opposite first and second ends such that a spring chamber is at least partially defined between the first and second ends; A first end member assembly according to any one of claims 1 to 15, said first end member assembly being operably connected to said elongated damper rod and operably secured to said first end of said flexible spring member so as to form a substantially fluid-tight connection therebetween; and, A second end member assembly is supported on the damper housing and operably secured to the second end of the flexible spring member such that a substantially fluid-tight connection is formed therebetween.

17. A suspension system, comprising: Compressed gas systems, including compressed gas sources and controls; and, At least one gas spring and damper assembly according to claim 16, arranged in fluid communication with said source of compressed gas via said control means so as to enable selective delivery of compressed gas into and out of at least said spring chamber.

18. A method of manufacturing an end member assembly dimensioned to be secured to an associated flexible spring member, the method comprising: providing a first end member, the first end member including a first end member wall formed at least in part from a first material, the first end member wall including a first side wall portion extending circumferentially about a longitudinal axis and a first flange wall portion extending radially outwardly from the first side wall portion, the first flange wall portion including a first first flange surface portion, a second first flange surface portion facing oppositely from the first first flange surface portion and sized to abuttingly engage an associated vehicle structure, and a third first flange surface portion facing oppositely from the first first flange surface portion and axially offset from the second first flange surface portion, the first flange wall portion including a plurality of attachment channels extending therethrough, the plurality of attachment channels being disposed in circumferentially spaced relationship to one another about the longitudinal axis; providing a second end member, the second end member including a second end member wall formed at least in part from a second material different from the first material, the second end member wall including a second side wall portion extending circumferentially about the longitudinal axis, a third side wall portion disposed radially outward of the second side wall portion and sized to receivably engage an associated flexible spring member therealong, and a second flange wall portion extending radially outwardly from at least one of the second side wall portion and the third side wall portion, the second flange wall portion including a first second flange surface portion, the second end member including a plurality of attachment studs integrally formed from the second material by the second end member wall, the plurality of attachment studs being disposed along the second flange wall portion in circumferentially spaced relationship to one another about the longitudinal axis, the plurality of attachment studs projecting axially from the first second flange surface portion; operably connecting a plurality of securing devices to the first end member such that the plurality of securing devices are disposed in circumferentially spaced relationship to one another about the longitudinal axis, one or more securing devices of the plurality of securing devices are disposed between adjacent ones of the plurality of attachment channels, the plurality of securing devices being accessible along the second first flange surface portion and operable to secure the second first flange surface portion of the first flange wall in abutting engagement along an associated vehicle structure; providing a sealing device formed at least in part from a third material and positioning the sealing device along one of the first sidewall portion of the first end member and the second sidewall portion of the second end member; positioning the first end member and the second end member axially coextensive with each other such that the sealing device is sealingly disposed between axially coextensive portions of the first side wall portion of the first end member and the second side wall portion of the second end member, such that the first first flange surface portion and the second first flange surface portion are disposed in facing relationship with each other such that the securing device is accessible from the second first flange surface portion along the first flange wall portion, the plurality of securing devices are rotationally oriented such that at least one of the plurality of securing devices is disposed between adjacent ones of the plurality of attachment channels, and such that at least one of the plurality of attachment studs extends through a respective one of the plurality of attachment channels and beyond the second first flange surface portion; as well as, A stud head is integrally formed along at least one of the plurality of attachment studs opposite the second flange wall portion so that the stud head is in abutting engagement with the third first flange surface portion of the first flange wall portion, thereby permanently maintaining the first end member and the second end member in an assembled state and so that the stud head is axially disposed between the second first flange surface portion and the third first flange surface portion, whereby the second first flange surface portion can be fixed in abutting engagement with an associated vehicle structure.

19. The method of claim 18, wherein each of the plurality of attachment studs extends through and cooperatively engages with a corresponding one of the plurality of attachment channels, and integrally forming a stud head along at least one of the plurality of attachment studs opposite to the second flange wall portion includes integrally forming a stud head along two or more of the plurality of attachment studs.

20. The method of any one of claims 18 and 19, further comprising capturing the plurality of fixing devices between the first flange wall portion and the second flange wall portion.

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