Gas spring end member assembly, gas spring assembly including same, and method of manufacture

Abstract

A gas spring end member assembly includes an end member body and an endless annular ring. The end member body includes a body wall formed from a polymeric material, the body wall having a crimp wall portion extending axially and dimensioned to receive an end of a gas spring flexible member. The endless annular ring is positioned in abutting engagement along an inside surface portion of the crimp wall portion. The endless annular ring provides increased radial stiffness to the crimp wall portion under a radially inward force to secure the end of the gas spring flexible member along the crimp wall portion. The crimp wall portion is disposed radially outward of the endless annular ring that frictionally engages the inboard surface portion of the crimp wall portion but is not constrained by the body wall in at least one axial direction. Gas spring assemblies, suspension systems, and methods of manufacture are also included.

Description

Background Art

[0001] The subject matter of the present disclosure relates broadly to the field of gas spring devices and, more particularly, to end member assemblies configured to provide increased radial stiffness and / or rigidity to a crimped connection while maintaining reduced residual stresses associated with its manufacture and use. Also included are gas spring assemblies having such end member assemblies and methods of assembly.

[0002] The subject matter of the present disclosure may be particularly applicable 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 assemblies, support structures, height adjustment systems, and actuators for such wheelless vehicles associated with industrial machinery, components thereof, and / or other equipment. Therefore, the subject matter of the present disclosure is not intended to be limited to uses associated with suspension systems for wheeled vehicles.

[0003] Most types and kinds of wheeled motor vehicles include a sprung mass (such as, for example, a body or chassis) and an unsprung mass (such as, for example, two or more axles or other wheel-engaging members between which a suspension system is disposed). Typically, the suspension system will include a plurality of spring elements and a plurality of damping devices 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, each of the plurality of damping devices is used to dissipate energy associated with undesired input and movement of a sprung mass, such as, for example, road surface inputs that occur during dynamic operation of a vehicle. Typically, such dampers are fluid-filled and operatively connected between a sprung mass and an unsprung mass, such as, for example, a vehicle body and an axle. An example of such a damping component is a conventional shock absorber commonly used in vehicle suspension systems.

[0005] The plurality of spring arrangements are used to accommodate the forces and loads associated with the operation and use of the vehicle. In some cases, the spring arrangements may take the form of gas spring assemblies that utilize 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 wall secured between relatively rigid end members. A variety of arrangements have been developed for securing the flexible wall to or along the end members, and it has been recognized that different securing arrangements have different advantages, such as, for example, low cost, improved sealing or reliability, high strength, and / or the ability to be disassembled and / or repaired.

[0006] Depending on the specific conditions under which the gas spring assembly is used, different securing devices may be employed in different applications. Additionally or alternatively, different gas spring end member configurations may be utilized depending on the specific conditions expected to be encountered by the connection between the flexible wall and the gas spring end member. As non-limiting examples, such conditions may include applications that may experience elevated internal gas pressures, overextension conditions, and / or exposure to low temperatures. In many cases, a different securing device may be selected and utilized on each of the two different end members of the gas spring assembly.

[0007] In some cases, a gas spring end member may include one or more components formed at least in part from a polymer material, such as, for example, to reduce weight and / or reduce manufacturing costs. In some such cases, the polymer end member component may include a wall portion to which or along which the end of the flexible sleeve is secured, such as by a crimping ring that presses radially inwardly against the end of the flexible sleeve. In such an arrangement, the end of the flexible sleeve is pressed radially inwardly against the polymer wall of the end member component, such that a substantially fluid-tight seal is formed between the end of the flexible sleeve and the polymer wall of the end member component. However, it has been recognized that in such structures, time-dependent viscoelastic effects may change the dimensions of the polymer wall, thereby reducing or otherwise adversely altering the integrity of the substantially fluid-tight connection between the end of the flexible sleeve and the polymer wall of the end member component.

[0008] To address this issue, some known polymer gas spring end member designs include a metal backing ring or support ring embedded within the polymer wall of the end member component. The metal backing ring provides radial rigidity to the polymer wall and can significantly retard viscoelastic creep that would otherwise occur over time. In many cases, such designs are manufactured by injection molding the polymer end member component onto the metal backing ring or support ring, such that the polymer wall is axially coextensive with the metal backing ring and located radially outward from the metal backing ring. In such cases, the injected polymer material flows around and along three sides of the metal backing ring. In such an arrangement, the metal backing ring is axially and radially trapped within the polymer material. However, in accordance with the presently disclosed subject matter, it has been recognized that when the end member component and the metal backing ring cool after the injection molding process, undesirably high localized stresses develop in certain areas of the end member component, such as near corners and / or edges of the metal backing ring. This is generally believed to be caused, at least in part, by the different coefficients of thermal expansion between the metal backing ring and the polymer materials of the end member component. Likewise, in accordance with the presently disclosed subject matter, it has been recognized that such undesirably high localized stresses may result in performance degradation and other adverse characteristics of known end member assemblies.

[0009] U.S. Patent No. 11,707,959 discloses an end member assembly for use in a gas spring assembly. The end member assembly comprises multiple components, at least one of which is formed from a polymer material, wherein a metal reinforcement ring is embedded within the polymer crimped wall of the end member component. In the disclosed arrangement, the metal reinforcement ring is axially and radially captured within the polymer wall of the end member component, as described above.

[0010] Despite the widespread use of known end member structures and corresponding securing devices, it is believed desirable to develop end members or end member assemblies for gas spring assemblies that can overcome the aforementioned and / or other disadvantages of known structures and provide improved retention, securing, and / or performance with respect to the connection to the flexible wall while promoting relatively low manufacturing costs, ease of assembly, and / or otherwise advancing the art of gas spring devices. Summary of the Invention

[0011] One example method of manufacturing a gas spring assembly having a longitudinal axis according to the presently disclosed subject matter may include forming an end member body extending axially between a first body end and a second body end. The end member body may include a body wall formed of a polymeric material. The body wall may extend circumferentially about the longitudinal axis and axially between the first body end and the second body end. The body wall may include a crimping wall portion extending axially and including a radially inwardly facing inner side surface portion and a radially outwardly facing outer side surface portion. The method may also include positioning a first endless annular ring formed separately from the end member body in abutting engagement with the inner side surface portion of the crimping wall portion of the end member body, thereby at least partially forming the end member assembly. The first endless annular ring may be positioned axially coextensive with at least a portion of the outer side surface portion of the crimping wall portion, wherein the first endless annular ring frictionally engages the inner side surface portion of the crimping wall portion, and wherein the first endless annular ring is not physically obstructed or otherwise constrained by the body wall in at least one axial direction. The method may also include positioning an end of a flexible wall of a gas spring flexible member that at least partially defines a spring chamber along the end member assembly such that the end of the flexible wall is disposed along the outer side surface of the crimp wall portion of the end member body. The method may also include positioning a second endless annular ring along the end of the flexible wall such that the second endless annular ring is axially coextensive with the crimp wall portion and the first endless annular ring. The method may also include radially displacing the second endless annular ring inwardly such that the second endless annular ring generates a radially inward force to compressively engage the flexible wall along the outer side surface of the crimp wall portion of the end member assembly. In such an arrangement, a fluid-tight seal is formed between the second endless annular ring and the flexible wall, wherein the first endless annular ring provides increased radial stiffness to the crimp wall portion under the action of the radially inward force.

[0012] An example of an end member assembly according to the subject matter of the present disclosure may be sized to receive an associated end of an associated gas spring flexible member. The end member assembly may include an end member body and an endless annular ring. The end member body may have a longitudinal axis and may extend axially between a first body end and a second body end. The end member body may include a body wall formed from a polymer material. The body wall may extend circumferentially about the longitudinal axis and extend axially between the first body end and the second body end. The body wall may include a crimping wall portion that extends axially and is sized to receive the associated end of the associated gas spring flexible member. The crimping wall portion may include a radially outwardly facing outer surface portion and a radially inwardly facing inner surface portion. The endless annular ring is formed separately from the end member body. The endless annular ring may be positioned to abut against the crimping wall portion along the inner surface portion of the crimping wall portion. The endless annular ring can be positioned axially coextensive with at least a portion of the outer side surface portion such that the endless annular ring provides increased radial stiffness to the crimp wall portion under a radially inward force associated with securing the associated end of the associated gas spring flexible member along the crimp wall portion. The crimp wall portion can be positioned radially outward of the endless annular ring, wherein the endless annular ring frictionally engages the inner side surface portion of the crimp wall portion but is unconstrained by the body wall in at least one axial direction.

[0013] One example of a gas spring assembly according to the subject matter of the present disclosure may include a gas spring flexible member having a longitudinal axis. The gas spring flexible member may include a flexible wall extending circumferentially about the longitudinal axis and extending axially between a first end and a second end to at least partially define a spring chamber between the first end and the second end. The end member assembly according to the preceding paragraph may be at least partially received within the first end of the gas spring flexible member such that a portion of the flexible wall is disposed along the outer surface portion of the crimping wall portion. An annular retaining ring may extend circumferentially about the longitudinal axis. The annular retaining ring may be positioned coextensive with the crimping wall portion and the endless annular ring. The annular retaining ring may be disposed radially outwardly of the flexible spring member and may generate a radially inward force to compressively engage the flexible wall along the outer surface portion of the crimping wall portion of the end member assembly such that a fluid-tight seal is formed between the annular retaining ring and the flexible wall.

[0014] Another example of a gas spring assembly according to the subject matter of the present disclosure may include a flexible spring member having a longitudinal axis. The flexible spring member may include a flexible wall extending circumferentially about the longitudinal axis between a first end and a second end of the flexible spring member, such that a spring chamber is at least partially defined between the first end and the second end. An end member may be fixed across the first end of the flexible wall, such that a fluid-tight connection is formed between the end member and the first end. Furthermore, an end member assembly may extend across the second end of the flexible wall. The end member assembly may include an end member body, which may extend circumferentially about the longitudinal axis. The end member body may include a body wall formed from a polymer material. The body wall may include a crimping wall portion, which includes a radially inwardly facing inner surface portion and a radially outwardly facing outer surface portion. The inner surface portion may extend axially between a first inner edge and a second inner edge, the second inner edge being axially offset from the first inner edge. The crimping wall portion may be received within the second end of the flexible spring member, such that the flexible wall is disposed along the outer surface portion. A first endless annular ring is formed separately from the end member body. The first endless annular ring may include an outer peripheral side surface portion, an inner peripheral side surface portion, and a first end surface portion oriented transversely to the longitudinal axis. The first endless annular ring may be positioned along the crimping wall portion such that the outer peripheral side surface portion is disposed in abutting engagement with the inner side surface portion of the crimping wall portion. The first endless annular ring frictionally engages the inner side surface portion of the crimping wall portion. Substantially all of the crimping wall portion from the second inner edge to the first inner edge is disposed radially outward of the first endless annular ring such that the first endless annular ring is substantially unconstrained by the crimping wall portion in at least one axial direction. A second endless annular ring may extend circumferentially around the longitudinal axis. The second endless annular ring may be positioned coextensive with the crimping wall portion of the end member body and with the first endless annular ring. The second endless annular ring may be disposed radially outward of the flexible spring member such that a portion of the flexible wall is disposed between the second endless annular ring and the crimping wall portion. The second endless annular ring may generate a radially inward force to compressively engage the flexible wall along the outer side surface portion of the crimp wall portion such that a fluid-tight seal is formed between the second endless annular ring and the flexible wall.

[0015] One example of a suspension system according to the presently disclosed subject matter may include a compressed gas system comprising a compressed gas source and a control device. The suspension system may also include at least one gas spring assembly according to either of the preceding two paragraphs. The at least one gas spring assembly may be placed in fluid communication with the compressed gas source via the control device such that compressed gas can be selectively delivered to and from the spring chamber. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 is a schematic diagram of one example of a suspension system for an associated vehicle including one or more gas spring assemblies (or gas spring and damper assemblies) in accordance with the presently disclosed subject matter.

[0017] Figure 2 is a top perspective view of one example of a gas spring and damper assembly including a gas spring assembly according to the presently disclosed subject matter.

[0018] Figure 3 yes Figure 2 Side elevation view of the gas spring and damper assembly.

[0019] Figure 4 yes Figure 2 and Figure 3 Magnified front elevation view of the gas spring and damper assembly.

[0020] Figure 5 yes Figures 2 to 4 Top plan view of the gas spring and damper assembly.

[0021] Figure 6 It is along Figure 5 The line 6-6 in the Figures 2 to 5 Cross-sectional side view of the gas spring and damper assembly.

[0022] Figure 7 yes Figures 2 to 6 Gas spring and damper assembly in Figure 6 An enlarged view of the portion marked as detail 7.

[0023] Figure 8 It is along Figure 7 The line 8-8 in the Figures 2 to 7 Cross-sectional plan view of the gas spring and damper assembly.

[0024] Figure 9 yes Figures 2 to 8 The end member components in Figure 7 An enlarged view of a portion of the image indicated as detail 9.

[0025] Figure 10 An alternative arrangement of end member assemblies according to the presently disclosed subject matter is illustrated.

[0026] Figure 11 Another alternative arrangement of an end member assembly according to the presently disclosed subject matter is illustrated.

[0027] Figure 12 is an enlarged exploded view of an end member assembly according to the presently disclosed subject matter, such as for example Figures 2 to 11 End member assembly shown.

[0028] Figure 13 is a graph illustrating predicted stresses for an end member assembly according to the presently disclosed subject matter undergoing otherwise conventional radially inward crimping actions.

[0029] Figure 14 is a graph illustrating the predicted stress of an end member assembly according to the presently disclosed subject matter, which is the predicted stress remaining after an otherwise conventional radially inward crimping action has ceased.

[0030] 15 illustrates an enlarged view of a conventional end member assembly with an overmolded backing ring.

[0031] 16 is a graph illustrating predicted stress for a conventional end member assembly having an overmolded backing ring, which is a residual predicted stress caused by the difference in coefficient of thermal expansion between the overmolded backing ring and the end member body.

[0032] 17 is a graph illustrating predicted stresses for a conventional end member assembly undergoing a conventional radially inward crimping action.

[0033] 18 is a graph illustrating the predicted stress of a conventional end member assembly, which is the predicted stress remaining after the conventional radially inward crimping action has ceased. DETAILED DESCRIPTION

[0034] Turning now to the drawings, it should be understood that the drawings are for the purpose of illustrating examples of the subject matter of the present disclosure, and that such examples are merely illustrative and are not intended to be construed as limiting. Additionally, it should be understood that the drawings are not drawn to scale and that portions of certain features and / or elements may be exaggerated for the purposes of clarity and / or ease of understanding.

[0035] Figure 1 An example of a suspension system 100 is illustrated that is operatively disposed between a sprung mass (such as, for example, an associated vehicle body BDY) and an unsprung mass (such as, for example, associated wheels WHL, associated axles AXL, and / or associated suspension components SCP of an associated vehicle VHC). It should be understood that one or more of the components of the suspension system can be operatively connected between the sprung and unsprung masses of the associated vehicle in any suitable manner. The suspension system includes one or more gas spring assemblies and one or more damper assemblies in accordance with the presently disclosed subject matter, which are operatively connected between the sprung and unsprung masses and, together, allow the sprung and unsprung masses of the associated vehicle to move relative to each other in a controlled manner, as discussed above.

[0036] 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, a gas spring assembly may be assembled with a damper assembly such 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 assemblies and components thereof according to the subject matter of the present disclosure are shown and described herein with particular reference to gas spring and damper assemblies. However, it should be recognized and understood that such configurations are optional and that the gas spring assemblies (and components and assemblies thereof) according to the subject matter of the present disclosure are not intended to be limited to use in gas spring and damper assemblies.

[0037] like Figure 1 As shown, 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, suspension system 100 may include a plurality of damper assemblies 104 operatively connected between the sprung mass and the unsprung mass of the vehicle. Depending on 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. Furthermore, the one or more gas spring assemblies and one or more damper assemblies may be operatively connected to, along, or otherwise between the sprung and unsprung masses 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 as a unit on, along, or otherwise between the sprung and unsprung masses.

[0038] The suspension system 100 also includes a compressed gas system 108 operatively associated with at least the gas spring assembly 102 for selectively providing compressed gas (e.g., air) thereto and selectively transferring compressed gas therefrom. Figure 1In the exemplary arrangement shown in , the compressed gas system 108 includes a compressed gas source, such as, for example, a compressor 110, for producing compressed air or other gas. A control device, such as, for example, a valve assembly 112, is shown as being in communication with the compressor 110 and can be of any suitable configuration 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, for example, a muffler 118, for exhausting the 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 period of time (e.g., seconds, minutes, hours, weeks, days, months).

[0039] The valve assembly 112 communicates with the gas spring assembly 102 via a suitable gas delivery line 122. Thus, compressed gas can be selectively delivered into and / or out of the gas spring assembly 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.

[0040] 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 valve assembly 112, such as via conductors or leads 128, for selectively operating and controlling the compressor and / or valve assembly, such as by providing compressed gas to the gas spring assembly 102 and exhausting compressed gas from the gas spring assembly. The controller 126 may be of any suitable type, kind, and / or configuration.

[0041] The control system 124 may also optionally include one or more sensing devices 130, such as, for example, operatively associated with the gas spring assembly 102 (or gas spring and damper assembly 106) 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 assembly (or gas spring and damper assembly); the distance between other components of the vehicle; the pressure or temperature associated with the gas spring assembly (or gas spring and damper assembly) and / or the pressure or temperature associated with a wheel or tire or other component associated with the gas spring assembly (or gas spring and damper assembly); and / or acceleration, load, or other input acting on the gas spring assembly (or gas spring and damper assembly). The sensing device 130 may be in communication with the ECU 126, which 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. Additionally, it should be understood that the sensing device may be of any suitable type, kind, and / or configuration, and may operate using any suitable combination of one or more operating principles and / or techniques.

[0042] Having described an example of a suspension system (e.g., suspension system 100) that may include a gas spring assembly according to the presently disclosed subject matter, the present invention will now be described in conjunction with Figures 2 to 14 An example of 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 FIG. 1 are shown to include a gas spring (or gas spring assembly) GS1 according to the subject matter of the present disclosure (such as, for example, may correspond to Figure 1 102 in the gas spring assembly). Additionally, the gas spring and damper assembly AS1 may optionally include a damper (or damper assembly) DP1, such as, for example, a damper assembly DP1 that may correspond to Figure 1 The gas spring assembly GS1 and the damper assembly DP1 may optionally be disposed in a coextensive arrangement with one another and may be operatively secured to one another in any suitable manner, such as, for example, described below. Figure 6 and Figure 7 As shown, a longitudinal axis AX extends longitudinally along the assembly AS1.

[0043] Damper assembly DP1 may include a damper housing 200 and a damper rod assembly 202 at least partially received within the damper housing. Damper housing 200 extends axially between housing ends 204 and 206 and includes a housing wall 208 that at least partially defines a damping chamber 210. 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 end 214 of damper rod assembly 202. Damper piston 218 is received within damping chamber 210 of damper housing 200 for reciprocating movement along the housing wall in a conventional manner. A volume of damping fluid 220 may be disposed within damping chamber 210, and damper piston 218 may be displaced through the damping fluid to dissipate kinetic energy acting on gas spring and damper assembly AS1. Although the damper assembly DP1 is shown and described herein as having a conventional structure in which 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.

[0044] That is, it should be understood that in some cases, the gas spring and damper assemblies 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 variety 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. Additionally, 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.

[0045] The housing wall 208 may define an opening (not numbered) along the housing end 204. A damper end wall 222 may extend through the opening and may be secured to or along the housing wall 218, forming a substantially fluid-tight connection therebetween. The damper end wall 222 may include an opening (not numbered) through which the elongated damper rod 216 may extend axially outward from the damping chamber 210 in a direction opposite the housing end 206. Additionally, the damper end wall (not numbered) may bridge the end 206 of the damper housing 200, forming a substantially fluid-tight connection therebetween. In some cases, an end cap 224 (sometimes referred to in the art as a strike cap) including an outer surface portion 226 may be supported on or along the end 204 of the damper housing 200. In other cases, the outer surface portion 228 of the housing wall 208 may be exposed at or along the end 204 of the damper housing.

[0046] An elongated damper rod 216 may project 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 externally accessible 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 damper assembly DP1 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.

[0047] 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 may be disposed toward and operatively connected to the associated unsprung mass. Figure 3 As shown, for example, the end 212 of the damper rod assembly 202 can be coupled to a first structural member or upper structural member USC (such as, for example, Figure 1 operatively coupled (directly or indirectly) to the associated vehicle body BDY in the vehicle and may be secured thereto in any suitable manner. As a non-limiting example, the gas spring assembly GS1 may include an end member (also referred to herein as an end member assembly) EM1 that may be secured to the upper structural component USC. One or more components of the gas spring assembly GS1 and / or one or more components of the damper assembly DS1 may be operatively connected to the end member assembly EM1. Additionally or alternatively, the damper assembly DP1 may include a mounting bracket 232 provided along the end 206 of the damper housing 200 that may be secured to a second or lower structural component LSC ( Figure 3 ) (such as Figure 1The second or lower structural component is fixed on or along the relevant axle AXL and / or relevant suspension component SCP in the vehicle body and can be fixed thereto in any suitable manner.

[0048] The gas spring assembly GS1 may include a flexible spring member 300 that extends 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 (also referred to herein as an end member assembly) 400 to which the end 304 of the flexible spring member 300 may be secured and an end member (also referred to herein as an end member assembly) 500 to which the end 212 of the damper rod assembly 202 may be operatively connected. Additionally or alternatively, the gas spring assembly GS1 may include an end member (also referred to herein as an end member assembly) 600 in accordance with the presently disclosed subject matter, which is supported on or along the damper housing 200. The end 306 of the flexible spring member 300 opposite the end member 400 may be secured to or along the end member assembly 600 in any suitable manner, such as, for example, described in greater detail below.

[0049] It should be clearly understood that an end member constructed in accordance with the subject matter of the present disclosure (which may alternatively be referred to herein as an end member assembly) may include one or more end member bodies. Therefore, the subject matter of the present disclosure is not intended to be limited to use in conjunction with an end member assembled from two or more end member bodies. Therefore, it should be clearly understood that the configuration of an end member including two or more end member bodies shown and described herein is merely exemplary and not intended to be limiting. Furthermore, it should be clearly understood that an end member according to the subject matter of the present disclosure may, in some cases, be configured to be fixed to or along one end of a flexible sleeve, such as for use as an "upper" end cap and / or an "upper" housing, and such end cap and / or housing may be formed by one or more end member bodies. Additionally or alternatively, an end member according to the subject matter of the present disclosure may, in some cases, be configured to be fixed to or along the other end of a flexible sleeve, such as for use as a "lower" end cap and / or a "lower" piston, and such end cap and / or piston may be formed by one or more end member bodies. Likewise, as indicated above, it should be clearly understood that the configurations of end members including two or more end member bodies shown and described herein are exemplary only and are not intended to be limiting.

[0050] For example, it should be clearly understood that end member assembly EM1 may optionally include components and structures in accordance with the subject matter of the present disclosure or otherwise be constructed with components and structures in accordance with the subject matter of the present disclosure, such as those components and structures described in more detail below. As another non-limiting example, it should be understood that end member 400 and / or end member 500 may optionally include components and structures in accordance with the subject matter of the present disclosure or otherwise be constructed with components and structures in accordance with the subject matter of the present disclosure, such as those components and structures described in more detail below. As yet another non-limiting example, it should be understood that end member assembly 600 may optionally include components and structures in accordance with the subject matter of the present disclosure or otherwise be constructed with components and structures in accordance with the subject matter of the present disclosure, such as those components and structures described in more detail below.

[0051] Additionally, it should be understood that the end member assembly 600 can be operatively supported on or along the damper housing 200 in any 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 fluid 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 sidewall portion 248 may include an outer side surface portion 226 that faces radially outward and forms an outermost peripheral extent of the damper assembly DP1 along the end 204 of the damper housing.

[0052] It should be understood that the flexible spring member 300 can have any suitable size, shape, structure and / or configuration. Additionally, the flexible spring member can be of any type and / or kind, such as a rolling cam or a spiral bellows structure. Figures 2 to 12 15 as including a flexible wall 308, which can be formed in any suitable manner from any suitable material or combination of materials. For example, the flexible wall may include one or more fabric-reinforced elastomeric plies or layers and / or one or more unreinforced elastomeric plies or layers. Typically, one or more fabric-reinforced elastomeric plies and one or more unreinforced elastomeric plies are used together and 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.

[0053] Flexible wall 308 may extend generally in a longitudinal direction between opposite ends 304 and 306. Additionally, flexible wall 308 may include an outer surface 310 and an inner surface 312. The inner surface may at least partially define spring chamber 302 of gas spring assembly GS1. In some cases, flexible wall 308 may include an outer or outer tire ply (not labeled) that at least partially forms outer surface 310. Additionally or alternatively, flexible wall 308 may also include an inner or inner tire ply (not labeled) that at least partially forms inner surface 312. In some cases, flexible wall 308 may also include one or more reinforcement plies (not shown) disposed between outer surface 310 and inner surface 312. The one or more reinforcement plies may have any suitable structure and / or configuration. For example, the one or more reinforcement plies may include one or more lengths of filament material at least partially embedded therein. Additionally, it should be understood that the one or more lengths of filament material, if any, 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.

[0054] The flexible spring member 300 can 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. For example, in some cases, according to the presently disclosed subject matter, the end member 400 can include an end member body 402 including an end member wall 404 having a crimp wall portion 406 and an endless annular ring 408 positioned axially coextensive with the crimp wall portion. As discussed in greater detail below in conjunction with the end member 600, the endless annular ring 408 is disposed in abutting engagement along an inner surface portion of the crimp wall portion to support the crimp wall portion against radially inward forces associated with attaching and retaining the end of the flexible wall of the flexible spring member to or along the crimp wall portion. As an example, the flexible spring member 300 may include ends that are secured to or along corresponding end members via one or more retaining (crimping) rings 314 and 316. Alternatively, a mounting bead (not shown) may be disposed along one of the ends of the flexible wall. In some cases, the mounting bead (if present) may optionally include a reinforcing element, such as, for example, an endless annular bead wire. In some cases, a restraining cylinder 318 and / or other components may be disposed radially outwardly along the flexible wall 308. In some cases, such components may be secured to or along the flexible wall in a suitable manner, such as, for example, by one or more backing rings 320 disposed in abutting engagement therewith.

[0055] 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 can be 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 6 As shown, the end member 500 may include one or more fasteners 502 operable to secure the end member assembly EM1 to a superstructure component USC such as, for example, Figure 1 The damper assembly DP1 may be operatively connected to the upper structural member via the end member assembly EM1 and may be operatively engaged with the end member assembly in any suitable manner. For example, the damper assembly DP1 may include a bushing 250 supported on or along the end member 500 and the damper rod assembly 202 may be secured to the bushing such as, for example, by a connector 252 engaging the connection structure 230 along the end 212 of the elongated damper rod 216. The bushing 250 may be supported on or along the end member 500 and may be operatively secured to the end member in any suitable manner. As a non-limiting example, the bushing 250 may be captured between the end member 500 and an end cap 254, which may be secured to or along the end member in a suitable manner such as, for example, by a retaining ring 256. In some cases, a connector fitting 258 may extend through the end cap 254 or be otherwise 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 .

[0056] It will be appreciated 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 the assembly AS1. For example, the damper assembly DP1 may include a jounce bumper 260 positioned on or along the elongated damper rod 216 within the spring chamber 302. It will be appreciated 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 fully jounced state of the assembly AS1. However, it will be appreciated that other configurations and / or arrangements may alternatively be used.

[0057] Additionally, as discussed above, the gas spring and damper assembly AS1 may undergo or otherwise experience relative rotation during displacement between the extended and compressed states. It will be appreciated that such relative rotation may be detrimental to the flexible spring member 300, and that the gas spring and damper assembly typically includes one or more features, components, and / or structures operable to isolate such relative rotation from the flexible spring member. For example, in some cases, the operative connection to the upper structural component USC may include one or more rotatable or torsionally movable components. In such cases, the end member assembly 600 may be supported directly on or along a support wall of the damper assembly in a substantially fixed rotational position. However, in other cases, the end member assembly EM1 may be fixed to or along the upper structural component USC in a substantially fixed rotational orientation. In such cases, the gas spring and damper assembly AS1 may include a torsional isolator 700 that may be supported on or along a support wall portion 234 of the damper assembly DP1. The torsional isolator 700 may include an elastomeric or compliant body 702 supported between a (relatively) rigid body 704 and a (relatively) rigid body 706. It will be appreciated that the compliant body 702 may be permanently affixed (i.e., not separable without damage, destruction, or material alteration of at least one of the component parts) to and / or between the rigid bodies 704 and 706, such as by a cured joint (e.g., vulcanization) and / or a flow of material joint.

[0058] The rigid body 704 can be operatively connected to the end member assembly 600 so as to maintain a substantially fixed rotational position therebetween. In some cases, a seal 708 can be sealingly disposed between the rigid body 706 and the damper housing 200 so as to form a fluid-tight arrangement therebetween. Additionally or alternatively, a seal 710 can be sealingly disposed between the rigid body 704 and the end member assembly 600 so as to form a fluid-tight arrangement therebetween. During use, the rigid body 706 is maintained in a substantially fixed rotational position relative to the damper assembly DP1, and the rigid body 704 is maintained in a substantially fixed rotational position relative to the end member assembly 600. Thus, the seal 708 and / or the seal 710 (if included) can each form a substantially static sealing arrangement between the corresponding components, rather than forming a dynamic sealing arrangement such as may be used in known structures. Thus, rotational displacements that may occur between one or more components of the damper assembly DP1 and one or more components of the gas spring assembly GS1 during use are isolated from (or at least significantly reduced) the flexible spring member 300 by deflection of the compliant body 702, which allows the rigid bodies 704 and 706 to rotate relative to each other about the longitudinal axis AX.

[0059] The end member assembly 600 is of a type and variety commonly referred to as a roll-out piston or roll-out piston assembly. It should be understood that the end member assembly 600 may include any suitable number of one or more components, structures, and / or elements. For example, the end member assembly 600 may include an end member body 602 including an end member (or body) wall 604 having any suitable number of one or more wall portions. As a non-limiting example of a suitable structure, the end member body 602 may optionally take the form of a two-piece body structure including an end member core 602C disposed along and supported on the damper housing 200, such as by a torsional isolator 700, as described above. Such optional structure for the end member body 602 may also include an end member housing (or one or more housing segments) 602S, which may be supported on or along the end member core. Regardless of the type and nature of the structure used, the end member body 602 can include an outer surface 606 along which the rolling cam 322 of the flexible spring member 300 can be displaced when the gas spring assembly GS1 (either alone or configured as a gas spring and damper assembly AS1) is displaced between a compressed state and an extended state. If included, it should be understood that the end member core 602C can be configured to receive and support one or more of the end member housings and / or housing segments 602S, such as those having any of a variety of different sizes, shapes, and / or configurations (e.g., outer profiles having different profiles and / or combinations of shapes). However, it should be recognized and understood that such a two-piece structure is not required and is merely exemplary. Therefore, it should be recognized and understood that the subject matter of the present disclosure is broadly applicable to end member assemblies and end member bodies thereof having other suitable structures and / or configurations. Therefore, any other end member assemblies and / or end member bodies thereof, such as, for example, those discussed above, may alternatively be used without departing from the subject matter of the present disclosure.

[0060] Additionally, it should be understood that the end member assembly 600 and one or more of its components and / or elements can be formed from 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 body 602 and its end member walls 604 can be formed from a suitable polymer material or combination of polymer 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).

[0061] The end member body 602 is shown as extending circumferentially about the axis AX and extending longitudinally between opposite ends 608 and 610. The end member body 602 can include a first or upper mounting section 612 toward the end 608, and the end 306 of the flexible spring member 300 can be operatively connected to or along the first or upper mounting section in a suitable manner. For example, the retaining ring 316 can be crimped or otherwise deformed radially inward to form a substantially fluid-tight connection between the end 306 of the flexible spring member 300 and the mounting section 612 of the end member body 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.

[0062] The end member wall 604 can include an outer or crimped wall portion 614 disposed toward the end 608, terminating in an end surface portion 616. In a preferred arrangement, the crimped wall portion 614 can take the form of an endless annular wall extending circumferentially around the end member body 602. In some cases, the crimped wall portion 614 can at least partially define an outermost periphery along a longitudinal segment of the end member body 602, such as, for example, along the upper mounting segment 612. The crimped wall portion 614 can include an inner side surface portion 618 extending circumferentially about the longitudinal axis AX and facing radially inward. The inner side surface portion 618 also extends axially from along an annular edge or axial extent 620 toward an annular edge or axial extent 622 that is offset from the annular edge 620 in the axial direction toward the end 610.

[0063] The crimping wall portion may also include an outer side surface portion 624 that extends circumferentially about the longitudinal axis AX and faces radially outwardly relative to the inner side surface portion 618. In some cases, the crimping wall portion may optionally include one or more engagement features disposed along its outer side surface portion that may be adapted to engage an end or other surface portion of the flexible spring member 300, thereby enhancing retention of the flexible spring member on the end member assembly in an assembled condition. As a non-limiting example, the crimping wall portion 614 may include a plurality of axially spaced, endless annular grooves 626 disposed along the outer side surface portion 624. However, it should be understood that other configurations and / or arrangements may alternatively be used.

[0064] The end member body 602 may also include a second or intermediate section 628 extending from along the upper mounting section 612 in a direction toward the end 610 of the end member body. The intermediate section 628 may include an outer side surface portion 630 that is dimensioned to receptively engage one or more of the end member housings or sections 602S, if included, that may be secured thereto in any suitable manner. As an example, the end member housing 602S may include a housing body wall portion 604S that may be divided into or alternatively formed into two or more end member housing segments 602S that may be assembled together around the intermediate section 628. However, it should be understood that other configurations and / or arrangements may alternatively be used. Additionally, the housing body wall portion 604S may include a contoured outer surface portion (not numbered) that at least partially forms the outer surface 606 of the end member assembly 600, along which the rolling cam 322 displaces during use.

[0065] The end member wall 604 of the end member body 602 may also include a third or lower mounting section 632 disposed at or along the end 610, which is sized or otherwise configured to at least partially support the end member assembly 600 in an axial direction on or along the damper assembly DP1. The end member wall 604 may also include an inner surface portion 634 that may at least partially define a passage 636 through the end member body 602. The end member wall 604 may optionally include one or more elongated ribs 638 that may be disposed in circumferentially spaced relation to one another about the axis AX and may extend longitudinally along the inner surface portion 634. If included, the elongated ribs 638 may be sized to form a slip fit or a clearance fit along the outer surface 228 of the damper housing 200.

[0066] It is well known that forming and maintaining a substantially fluid-tight seal between the end of a flexible spring member and an associated end member or end member assembly provides desirable performance characteristics for gas spring assemblies. Therefore, in some known configurations, an end wall portion EWP of a flexible sleeve FSL is secured along a crimp wall portion CWP of an end member EMB using a retaining ring RTR that is radially displaced inwardly, causing the end wall portion EWP to be compressed between the crimp wall portion CWP and the retaining ring RTR, as shown, for example, in FIG15 . It is recognized that end members formed of a polymeric material deflect radially inwardly under the action of forces associated with the radially inward deformation of the retaining ring RTR, thereby pressing the end wall portion EWP against the crimp wall portion CWP. Therefore, some known configurations include a backing ring BKR embedded within the end member EMB, extending radially inwardly of and axially along the crimp wall portion CWP. The backing ring BKR is typically formed of metal or another material having significantly greater rigidity than the polymeric material of the end member EMB. Thus, in the known structure, the backing ring BKR supports the crimping wall portion CWP. Thus, the combination of the crimping wall portion CWP and the backing ring BKR increases the radial rigidity of the crimping wall portion to resist the forces associated with the radially inward deformation of the retaining ring RTR to press the end wall portion EWP against the crimping wall portion CWP, this deformation being caused by a process or effect generally referred to as time-dependent viscoelastic creep.

[0067] It is common practice to manufacture the end member EMB with a backing ring BKR embedded within the crimped wall portion CWP, such that the backing ring is captured in both axial directions by the polymer material of the end member. Typically, the backing ring BKR will take the form of an endless annular ring comprising an outer side surface OSS, an inner side surface ISS, and opposing end surfaces ES1 and ES2. In many cases, the end member EMB is formed by an injection molding (or other similar) process, wherein the backing ring BKR is inserted into a mold cavity before injecting the polymer material in a flowable form (e.g., molten). Using such manufacturing techniques, a mold section MSC at least partially defines the innermost extent of the mold cavity, within which the backing ring BKR is disposed, and within which the flowable polymer material is injected to form the end member EMB around the backing ring BKR. In many cases, the mold section MSC will be adjacently engaged with or at least form a tight fit with the backing ring BKR to substantially inhibit the flow of the polymer material along at least a portion of the inner side surface ISS. However, the mold cavity is typically configured so that end member wall portion WP1 is formed along end surface ES1 and end member wall portion WP2 is formed along end surface ES2 of the backing ring.In some cases, end member wall portion WP3 may be formed along at least a portion of inside surface ISS.

[0068] In such known structures, the backing ring BKR is typically captured in both axial directions by end member wall portions WP1 and WP2, the material of which is molded around the backing ring's opposing end surfaces ES1 and ES2. Additionally, in some cases, such known structures may include an end member wall portion WP3 disposed along at least a portion of the inner side surface ISS of the backing ring BKR. It has been recognized that known structures and manufacturing methods may undesirably induce stresses within the polymer material of the end member EMB of sufficient magnitude to result in reduced performance and / or a shortened lifespan of these conventional structures.

[0069] More specifically, Figures 16 to 18 illustrate graphical representations of stresses within the polymer material of the end member EMB under various manufacturing and use conditions. Because the end member EMB is formed from a polymer material and the backing ring BKR is typically formed from a metal material (e.g., steel or aluminum), the difference in the coefficient of thermal expansion of each material causes the size of the end member and the embedded backing ring to change at different rates as the assembly cools when removed from the injection mold. As a result, in certain regions within the polymer material of the end member EMB, particularly in certain regions where the polymer material interfaces with the backing ring BKR, residual stresses with undesirably high values ​​may be generated, such as illustrated by regions PSA, PSB, and PSC in Figure 16, where the stresses in these regions are significantly higher than the stresses in other regions of the end member. For example, as estimated using finite element modeling and analysis, the stress in region PSA is predicted to exceed approximately 200 MPa, while the stresses in regions PSB and PSC are predicted to be equal to or exceed 160 MPa and 110 MPa, respectively.

[0070] Additionally, it has been recognized that the act of crimping or otherwise generating a radially inward force (as indicated by arrows CMF) to deform the retaining ring RTR radially inward and thereby compressively engage the end wall portion EWP of the flexible sleeve FSL along the crimped wall portion CWP can, to some extent, alleviate the undesirably high stresses associated with the cooling process in one or more previously identified regions of the polymer material interfacing with the backing ring BKR. However, it has been recognized that such residual stresses can remain at undesirably high levels. For example, FIG. 17 illustrates stresses in regions PSA, PSB, and PSC, which, as estimated using finite element modeling and analysis, are predicted to potentially exceed approximately 145 MPa in region PSA, approximately 60 MPa in region PSB, and approximately 40 MPa in region PSC. Furthermore, it has been recognized that even when the crimping force CMF associated with deforming the retaining ring RTR is reduced, undesirably high residual stresses can remain in one or more of the aforementioned regions of the polymer material interfacing with the backing ring BKR. That is, once the retaining ring RTR has been deformed to the final crimped state and the end wall portion EWP is compressively disposed between the crimped wall portion CWP and the retaining ring, residual stresses having undesirably high values ​​are expected to remain in one or more of the aforementioned regions within the polymer material of the end member EMB. For example, FIG18 illustrates the stresses in regions PSA, PSB, and PSC, and as estimated using finite element modeling and analysis, these stresses are predicted to potentially exceed approximately 150 MPa in region PSA, approximately 60 MPa in region PSB, and approximately 40 MPa in region PSC.

[0071] With further reference now to the subject matter of the present disclosure, Figure 6 、 Figure 7 and Figure 9 A non-limiting example of an end member assembly 600 is illustrated that includes an endless annular ring 640 disposed along a crimping wall portion 614. The endless annular ring 640, which may also be referred to in the art as a backing ring, is used to support the crimping wall portion 614 against radially inward forces associated with crimping or other radially inward deformation of the retaining ring 316 to compressively engage the end wall portion 324 of the flexible wall 308 between the retaining ring and the crimping wall portion. Such radially inward forces are Figures 9 to 11 640 is axially extending from an end surface portion 646 toward an end surface portion 648 that is offset from the end surface portion 646, such that the endless annular ring has a ring height defined between the two end surface portions, such as at Figures 9 to 11In a preferred arrangement, the endless annular ring 640 is formed from a metallic material or a polymeric material having significantly increased rigidity relative to the polymeric material of the end member body 602 , and in particular the crimp wall portion 614 .

[0072] In a preferred arrangement, the axial extent 622 of the inside surface portion 618 of the crimp wall portion 614 is axially offset from the axial extent 620 such that the inside surface portion 618 has an inside surface portion height, such as at Figures 9 to 11 Additionally or alternatively, the axial extent 622 is axially offset from the end surface portion 616 such that the inner side surface portion 618 has an overall axial extent or depth, such as at Figure 9 In a preferred arrangement, the inside surface portion height SPH (and overall axial depth OAD) may be greater than the ring height RHT, such as at least Figure 9 In such an arrangement, the endless annular ring 640 may be positioned along the inside surface portion 618 such that at least one annular section of the inside surface portion 618 of the crimping wall portion 614 is axially exposed outside of the endless annular ring 640. Figure 6 、 Figure 7 and Figure 9 In the illustrated arrangement, the exposed annular section EX1 extends between the end surface portion 646 and the axial extent 620 of the inside surface portion. In such an arrangement, the endless annular ring 640 can optionally be positioned relative to the end member wall 604 such that the end surface portion 648 of the endless annular ring 640 is at least approximately coplanar with the axial extent 622 of the inside surface portion 618 of the crimp wall portion 614. Figure 10 An alternative arrangement is shown in , in which an endless annular ring 640 is positioned along the inner surface portion 618 such that an exposed annular segment EX1 extends between an end surface portion 646 and an axial extent 620 , with another exposed annular segment EX2 extending between an end surface portion 648 and an axial extent 622 . Figure 11 6, wherein the endless annular ring 640 is positioned along the inner side surface portion 618 such that the exposed annular segment EX1 extends between the end surface portion 646 and the axial extent 620. Additionally, the end member wall 604 includes an inner wall portion 650 that extends axially from along the axial extent 620 in a direction toward the axial extent 622. The inner wall portion 650 includes an end surface portion 652 that is axially offset from the axial extent 622 of the inner side surface portion 618. The inner wall portion 650 also includes an outer side surface portion 654 that extends circumferentially about the axis AX and extends axially between the axial extent 622 and the end surface portion 652 such that an annular channel or groove 656 ( Figure 12) is radially disposed between the inner surface portion 618 and the outer surface portion 654. In such an arrangement, the endless annular ring 640 can optionally be positioned relative to the end member wall 604 such that the end surface portion 648 of the endless annular ring 640 is at least approximately coplanar with the axial extent 622 of the inner surface portion 618 of the crimp wall portion 614.

[0073] It should be understood that the inner side surface portion 618 of the crimping wall portion 614 is configured to have no end member wall portion (e.g., end member wall portion WP1 in FIG. 15 ) extending radially inward from any substantial portion of the endless annular ring 640. In a preferred arrangement, the inner side surface portion 618 can be configured to have no such end member wall portion extending radially inward beyond any substantial portion of the endless annular ring 640 from axially along the axial extent 620 to at least the axial extent 622, preferably to the end surface portion 616. Thus, the inner side wall portion 618 forms an open end 658 having an unobstructed side surface portion sized to receive the endless annular ring 640. In some cases, the inner side surface portion 618 can have an approximately linear cross-sectional profile. In some cases, the approximately linear cross-sectional profile can be arranged to be approximately aligned with the longitudinal axis AX. In such cases, the cross-sectional profile can sweep about the axis AX to produce an inner side surface portion 618 having an approximately cylindrical shape or configuration. In a preferred arrangement, in the assembled state, all or substantially all of the crimping wall portion 614 is disposed radially outwardly of the endless annular ring 640. In such a configuration, the endless annular ring 640 may be disposed separately from the end member body 602. The endless annular ring 640 may be axially displaced (e.g., pressed or otherwise axially urged) into axially coextensive engagement with at least a portion of the crimping wall portion 614, such as in Figure 12 6 is indicated by arrow ADP, which represents the axial displacement of the endless annular ring relative to the end member body 602.

[0074] Preferably, the inside surface portion 618 of the crimping wall portion 614 and the outside surface portion 644 of the endless annular ring 640 will be sized to form a press fit or transition fit with each other. Thus, the endless annular ring 640 can be displaced into axially coextensive engagement with the crimping wall portion 614 and held in place by frictional engagement between the surface portions 618 and 644, such as in Figures 9 to 11 640 along the crimped wall portion 614. Figure 12660. In any event, the endless annular ring 640 is positioned and retained on or along the crimped wall portion 614 to increase radial rigidity without axially capturing the endless annular ring between the polymeric wall portions of the end member body, which could create undesirable stresses within the polymeric material, as described in detail above in conjunction with conventional structures.

[0075] As a non-limiting example, Figure 13 and Figure 14 16 illustrates a graphical representation of the stresses within the polymer material of the end member body 602 under various conditions of use. As discussed above, the endless annular ring 640 is provided separately from the end member body 602, which is manufactured from a polymer material separate from the endless annular ring 640, such as, for example, by an injection molding process. Because the endless annular ring is not insert molded into the end member body, the residual stresses illustrated in FIG. 16 that are typically associated with cooling components having different coefficients of thermal expansion are substantially completely eliminated from the end member assembly in accordance with the presently disclosed subject matter. Therefore, the present disclosure does not include any further examples of the presently disclosed subject matter. Figure 6 、 Figure 7 and Figures 9 to 12 A graphical representation of the structure of the end member body 602 is shown, wherein the residual stresses arise from cooling of the multi-material structure. Figure 13 and Figure 14 It will be appreciated that the region PSA of Figures 16 to 18 is not present in Figure 18 because there is no corresponding geometric feature of the end member body 602 (ie, there is no equivalent of the end member wall portion WP1 in Figure 15). Figure 13 and Figure 14 It does not exist at all.

[0076] Eliminating residual stresses associated with cooling components having different coefficients of thermal expansion than the end member body 602 also significantly reduces (or nearly eliminates) stresses within the end member body during and after undergoing the crimping process, such as described in detail above with respect to known structures in conjunction with Figures 17 and 18. Figure 13 and Figure 14 exemplifies the residual stresses having lower, more desirable values ​​within the remaining regions of the end member body 602, as identified by regions PSB and PSC. More specifically, Figure 13 The stresses associated with the action of crimping or otherwise generating a radially inward force are illustrated, as represented by arrows CMF, to deform the retaining ring 316 radially inward to compressively engage the end wall portion 324 of the flexible wall 308 along the crimping wall portion 614 (as radially supported by the endless annular ring 640). As an example, Figure 13The stresses in regions PSB and PSC are shown in , and as estimated using finite element modeling and analysis, the stress in region PSB is predicted to be less than about 3 MPa, and the stress in region PSC is less than 3 MPa.

[0077] Figure 14 316. Residual stresses within the end member body 602 are illustrated as the crimping force CMF associated with deforming the retaining ring 316 decreases. That is, once the retaining ring 316 has been deformed to the final crimped state and the end wall portion 324 is compressively disposed between the crimping wall portion 614 and the retaining ring 316, residual stresses having lower, more desirable values ​​remain in one or more of the aforementioned regions within the polymer material of the end member body 602. Again, as an example, Figure 14 16-18, and significantly reduce the stress in regions PSB and PSC, as estimated using finite element modeling and analysis. Figure 13 The difference between the comparison and Figure 17 and Figure 14 18 and the comparative differences between FIG.

[0078] Additionally, for reference purposes, areas are identified by the reference characters PSD as having stresses on or along the crimp wall portion 614. More specifically, area PSD represents the stresses associated with the crimp connection of the end wall portion 324 on or along the outside surface portion 624 of the crimp wall portion 614, the stresses being generated by or otherwise created by the retaining ring 316 compressively engaging the crimp wall portion when supported by the endless annular ring 640. It should be understood that the crimp wall portion 614 may be designed or otherwise configured to accommodate stresses of greater magnitude than in other areas of the end member body 602. For example, as estimated using finite element modeling and analysis, the stresses in area PSD may be greater than those in area PSD. Figure 13 is shown to be predicted to be less than about 50 MPa, and Figure 14 is shown to be predicted to be less than about 40 MPa.

[0079] 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 individual or otherwise identify certain features, elements, components and / or structures, and do not imply any order or sequence unless expressly provided by the claim language. Additionally, the terms "transverse" and the like are interpreted broadly. Because of this, the terms "transverse" and the like may include a wide range of relative angular orientations, which include but are not limited to approximately vertical angular orientations. Additionally, the terms "circumferential," "circumferentially," and the like 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," and the like may be synonymous with terms such as "peripheral," "peripherally," and the like.

[0080] 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, one or more metallic materials and / or alloys may be used to form such flowing material joints, in addition to any materials derived from the components themselves. 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.

[0081] Furthermore, the term "gas" as used herein refers broadly to any gaseous or aerosol fluid. Most commonly, air is used as the working medium for gas spring devices such as those described herein, as well as suspension systems and other components thereof. However, it should be understood that any suitable gaseous fluid may be used.

[0082] 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 expressly 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 limitation. Therefore, it should be clearly understood that claims directed to any such combination of features and / or components, whether or not specifically embodied herein, are intended to find support in this disclosure. To assist the Patent Office and any reader of this application and any resulting patent used to interpret the claims appended hereto, Applicant does not intend that any of the appended claims or any claim element be invoked under 35 U.S.C. 112(f) unless the words "means for..." or "step for..." are expressly used in a particular claim.

[0083] Therefore, although the subject matter of the present disclosure has been described with reference to the above-described embodiments and considerable emphasis has been placed herein on the structures and structural interrelationships between the component parts of the disclosed embodiments, it should be understood that other embodiments may be constructed and that many changes may be made to the illustrated and described embodiments without departing from the principles of the present invention. Obviously, other aspects will be modified and altered after reading and understanding the foregoing detailed description. Therefore, it should be clearly understood that the above-described descriptive issues are to be interpreted as merely illustrative and not restrictive of the subject matter of the present disclosure. As such, it is intended that the subject matter of the present disclosure be understood to include all such variations and modifications.

Claims

1. A method of manufacturing a gas spring assembly comprising a longitudinal axis, the method comprising: an end member body formed to extend axially between a first body end and a second body end, the end member body including a body wall formed of a polymeric material, the body wall extending circumferentially about the longitudinal axis and extending axially between the first body end and the second body end, the body wall including a crimp wall portion extending axially and including a radially inwardly facing inner side surface portion and a radially outwardly facing outer side surface portion; positioning a first endless annular ring formed separately from the end member body in abutting engagement with an inside surface portion of the crimp wall portion of the end member body to at least partially form an end member assembly, the first endless annular ring being disposed axially coextensive with at least a portion of the outside surface portion of the crimp wall portion, wherein the first endless annular ring frictionally engages the inside surface portion of the crimp wall portion, wherein the first endless annular ring is not physically obstructed or otherwise constrained by the body wall in at least one axial direction; positioning an end of a flexible wall of a gas spring flexible member at least partially defining a spring chamber along the end member assembly such that the end of the flexible wall is disposed along the outside surface of the crimp wall portion of the end member body; positioning a second endless annular ring along the end of the flexible wall such that the second endless annular ring is axially coextensive with the crimp wall portion and the first endless annular ring; as well as The second endless annular ring is displaced radially inwardly such that the second endless annular ring generates a radially inward force to compressively engage the flexible wall along the outer side surface portion of the crimping wall portion of the end member assembly to form a fluid-tight seal between the second endless annular ring and the flexible wall, wherein the first endless annular ring provides increased radial rigidity to the crimping wall portion under the action of the radially inward force.

2. The method of claim 1 , wherein forming the end member body comprises: A plurality of annular grooves are in axially spaced relationship with one another along the crimp wall portion, and positioning the end of the flexible wall includes positioning the end of the flexible wall along the plurality of annular grooves.

3. The method of claim 2, wherein displacing the second endless annular ring radially inward comprises: A radially inward force is generated to compressively engage the ends of the flexible wall with the plurality of annular grooves.

4. The method according to any one of claims 1 to 3, wherein the polymer material of the end member body is a first polymer material, and the method further comprises: The first endless annular ring is provided separately from the end member body, the end member body being formed from one of a metallic material and a second polymeric material that is different from the first polymeric material of the end member body.

5. The method of any one of claims 1 to 4, wherein the inner side surface portion of the crimping wall portion extends axially between a first inner edge disposed toward the first body end and a second inner edge disposed toward the second body end relative to the first inner edge, the first endless annular ring includes a radially outwardly facing outer peripheral side surface portion, a radially inwardly facing inner peripheral side surface portion, and a first end surface portion oriented transverse to the longitudinal axis, and positioning the first endless annular ring comprises: The first endless annular ring is axially displaced relative to the end member body such that the outer peripheral side surface portion is placed in abutting engagement with the inner side surface portion of the crimp wall portion.

6. The method of claim 5, wherein axially displacing the first endless annular ring relative to the end member body comprises: The first endless annular ring is axially displaced until the first end surface portion is offset from the first inner edge by a first offset distance such that an exposed annular section of the inside surface portion of the crimp wall portion extends from along the first end surface portion of the first endless annular ring to the first inner edge.

7. The method of any one of claims 5 and 6, wherein the first endless annular ring includes a second end surface portion that is offset from the first end surface portion such that a ring height is defined therebetween, and axially displacing the first endless annular ring relative to the end member body comprises: The first endless annular ring is axially displaced until the second end surface portion is offset from the second inner edge by a second offset distance such that an exposed annular section of the inside surface portion of the crimping wall portion extends from the second end surface portion along the first endless annular ring to the second inner edge.

8. The method of any one of claims 5 and 6, wherein the first endless annular ring includes a second end surface portion that is offset from the first end surface portion such that a ring height is defined therebetween, and axially displacing the first endless annular ring relative to the end member body comprises: The first endless annular ring is axially displaced until the second end surface portion is substantially coplanar with the second inner edge.

9. The method according to any one of claims 1 to 8, wherein the end member body includes a distal surface portion disposed along the first body end, the inner side surface portion of the crimping wall portion extends axially inward from along the first body end between a first inner edge disposed toward the first body end and a second inner edge disposed toward the second body end relative to the first inner edge, and forming the end member body comprises: The end member body is formed so that substantially the entirety of the end member body extending axially outward from the second inner edge along the inner side surface portion to the distal end surface portion of the end member body is disposed radially outside the crimping wall portion so that the first endless annular ring is not obstructed by the crimping wall portion from the second inner edge of the inner side surface portion to the distal end surface portion of the end member body.

10. The method of any one of claims 1 to 8, wherein forming the end member body comprises: Forming the body wall with an inner wall portion, the inner wall portion being disposed radially inwardly of and axially coextensive with the crimp wall portion, such that an annular channel is disposed between the inner side surface portion of the crimp wall portion and the outer side wall portion of the inner wall portion, and positioning the first endless annular ring in abutting engagement along the inner side surface portion of the crimp wall portion includes positioning at least a portion of the first endless annular ring within the annular channel.

11. An end member assembly sized to receive an associated open end of an associated gas spring flexible member, the end member assembly comprising: an end member body having a longitudinal axis and extending axially between a first body end and a second body end, the end member body including a body wall formed of a polymeric material, the body wall extending circumferentially about the longitudinal axis and extending axially between the first body end and the second body end, the body wall including a crimp wall portion extending axially and including a radially inwardly facing inner side surface portion, and the crimp wall portion including a radially outwardly facing outer side surface portion, and the outer side surface portion being sized to receive the associated open end of the associated gas spring flexible member along the outer side surface portion; and an endless annular ring formed separately from the end member body, the endless annular ring positioned in abutting engagement with the crimp wall portion along the inner side surface portion of the end member body and disposed axially coextensive with at least a portion of the outer side surface portion such that the endless annular ring provides increased radial rigidity to the crimp wall portion under the action of a radially inward force associated with securing the associated open end of the associated gas spring flexible member along the crimp wall portion; The crimping wall portion is disposed radially outwardly of the endless annular ring, wherein the endless annular ring frictionally engages the inner side surface portion of the crimping wall portion but is not constrained by the body wall in at least one axial direction.

12. The end member assembly of claim 11 wherein the outer side surface portion includes a plurality of annular grooves in axially spaced relationship to one another along the crimp wall portion, the plurality of annular grooves for engaging the associated gas spring flexure member.

13. The end member assembly of any one of claims 11 and 12, wherein the crimp wall portion of the body wall has a first radial stiffness and the endless annular ring has a second radial stiffness, such that a combination of the first radial stiffness and the second radial stiffness is greater than the first radial stiffness alone.

14. The end member assembly of claim 13, wherein the second radial stiffness of the endless annular ring is greater than the first radial stiffness of the crimped wall portion.

15. The end member assembly of any one of claims 11 to 14, wherein the endless annular ring is formed of a material different from the polymeric material of the body wall.

16. The end member assembly of any one of claims 11 to 15, wherein the polymeric material of the body wall is a first polymeric material and the endless annular ring is formed from one of a metallic material and a second polymeric material, the second polymeric material being different from the first polymeric material.

17. The end member assembly according to any one of claims 11 to 16, wherein the endless annular ring includes a radially outwardly facing outer peripheral side surface portion and a radially inwardly facing inner peripheral side surface portion, wherein the outer peripheral side surface portion is configured to be in abutting engagement with the inner side surface portion of the crimping wall portion.

18. The end member assembly of claim 17, wherein the endless annular ring includes a first end surface portion oriented transverse to the longitudinal axis and a second end surface portion axially offset from the first end surface portion, wherein the outer peripheral side surface portion and the inner peripheral side surface portion extend about the longitudinal axis between the first end surface portion and the second end surface portion.

19. The end member assembly of claim 18, wherein substantially all of the crimp wall portion extending from the first end surface portion along the endless annular ring in a direction opposite to the second end surface portion is disposed radially outside the crimp ring.

20. The end member assembly of any one of claims 11 to 19, wherein the inner side surface portion extends axially between a first inner edge disposed toward the first body end and a second inner edge disposed toward the second inner edge relative to the first inner edge.

21. The end member assembly of claim 20, wherein the endless annular ring includes a radially outwardly facing outer peripheral side surface portion, a radially inwardly facing inner peripheral side surface portion, and a first end surface portion oriented transversely to the longitudinal axis, the outer peripheral side surface portion being configured to abut engagement with the inner side surface portion of the crimping wall portion, and the first end surface portion being axially offset from the first inner edge by a first offset distance.

22. The end member assembly of claim 21, wherein the exposed annular section of the inside surface portion of the crimp wall portion extends from along the first end surface portion of the endless annular ring to the first inner edge.

23. The end member assembly of any one of claims 21 and 22, wherein the endless annular ring includes a second end surface portion offset from the first end surface portion such that a ring height is defined therebetween.

24. The end member assembly of claim 23, wherein the exposed annular section is a first exposed annular section and a second exposed annular section of the inside surface portion of the crimp wall portion extends from the second end surface portion along the endless annular ring to the second inner edge.

25. The end member assembly of any one of claims 20 to 24, wherein substantially all of the crimp wall portion from the second inner edge to the first inner edge is disposed radially outwardly of the endless annular ring.

26. The end member assembly according to any one of claims 11 to 25, wherein the inner side surface portion of the crimping wall portion has a cylindrical shape.

27. A gas spring assembly, comprising: a gas spring flexible member having a longitudinal axis, the gas spring flexible member including a flexible wall extending circumferentially about the longitudinal axis and extending axially between a first end and a second end to at least partially define a spring chamber between the first end and the second end; and The end member assembly of any one of claims 11 to 26, the end member assembly being at least partially received within the first end of the gas spring flexible member such that a portion of the flexible wall is disposed along the outer side surface portion of the crimp wall portion; and an annular retaining ring extending circumferentially about the longitudinal axis, the annular retaining ring being positioned coextensive with the crimp wall portion and the endless annular ring, the retaining ring being disposed radially outward of the flexible spring member and generating a radially inward force to compressively engage the flexible wall along the outer side surface portion of the crimp wall portion of the end member assembly such that a fluid-tight seal is formed between the annular retaining ring and the flexible wall.

28. A gas spring assembly, comprising: a flexible spring member having a longitudinal axis and including a flexible wall extending circumferentially about the longitudinal axis between a first end and a second end of the flexible spring member so as to at least partially define a spring chamber between the first end and the second end; an end member secured across the first end of the flexible wall such that a fluid-tight connection is formed between the end member and the first end; an end member assembly extending across the second end of the flexible wall, the end member assembly comprising: an end member body extending circumferentially about the longitudinal axis, the end member body including a body wall formed of a polymeric material, the body wall including a crimp wall portion, the crimp wall portion including a radially inwardly facing inner side surface portion and a radially outwardly facing outer side surface portion, the inner side surface portion extending axially between a first inner edge and a second inner edge, the second inner edge being axially offset from the first inner edge, the crimp wall portion being received within the second end of the flexible spring member such that the flexible wall is disposed along the outer side surface portion; and a first endless annular ring formed separately from the end member body, the first endless annular ring comprising an outer peripheral side surface portion, an inner peripheral side surface portion, and a first end surface portion oriented transverse to the longitudinal axis; the first endless annular ring being positioned along the crimping wall portion such that the outer peripheral side surface portion is disposed in abutting engagement with the inner side surface portion of the crimping wall portion, the first endless annular ring frictionally engaging the inner side surface portion of the crimping wall portion, wherein substantially all of the crimping wall portion from the second inner edge to the first inner edge is disposed radially outward of the first endless annular ring such that the first endless annular ring is unencumbered by the crimping wall portion in at least one axial direction; and a second endless annular ring extending circumferentially about the longitudinal axis, the second endless annular ring being positioned coextensive with the crimp wall portion of the end member body and coextensive with the first endless annular ring, the second endless annular ring being disposed radially outwardly of the flexible spring member such that a portion of the flexible wall is disposed between the second endless annular ring and the crimp wall portion, the second endless annular ring generating a radially inward force to compressively engage the flexible wall along the outer surface portion of the crimp wall portion such that a fluid-tight seal is formed between the second endless annular ring and the flexible wall.

29. The gas spring assembly of claim 28, wherein the exposed annular section of the inner side surface portion of the crimp wall portion extends from along the first end surface portion of the first endless annular ring to the first inner edge, wherein the exposed annular section extends substantially aligned with the outer peripheral side surface portion of the first endless annular ring.

30. The gas spring assembly of claim 29, wherein the exposed annular section is a first exposed annular section and a second exposed annular section of the inside surface portion of the crimp wall portion extends from along the second end surface portion of the first endless annular ring to the second inner edge.

Images