Gas spring assemblies with internal rebound-limiting assemblies and suspension systems including same

Abstract

Gas spring assemblies include first and second end members. A first flexible annular member is secured between the first and second end members to at least partially define a spring chamber. A second flexible annular member is disposed within the spring chamber and secured between the first and second end members. Upon displacement of the first and second end members away from one another during extension of the gas spring assembly, the second flexible annular member reaches a second maximum extensible length prior to the first flexible annular member reaching a first maximum extensible length thereby substantially inhibiting the first flexible annular member from reaching the first maximum extensible length. The second flexible annular member separates the spring chamber into inner and outer chamber portions that are disposed in fluid communication with one another.

Description

GAS SPRING ASSEMBLIES WITH INTERNAL REBOUND-LIMITING ASSEMBLIES AND SUSPENSION SYSTEMS INCLUDING SAMEBACKGROUND

[0001] The subject matter of the present disclosure broadly relates to the art of gas spring devices and, more particularly, to rebound-limiting devices that are dimensioned for securement between opposing end member assemblies and operable to inhibit inadvertent overextension of gas spring assemblies. Suspension systems that include one or more of such gas spring assemblies are also included.

[0002] The subject matter of the present disclosure may find particular application and use in conjunction with components for wheeled vehicles, and will be shown and described herein with reference thereto. However, it is to be appreciated that the subject matter of the present disclosure is also amenable to use in other applications and environments, and that the specific uses shown and described herein are merely exemplary. For example, the subject matter of the present disclosure could be used in connection with gas spring assemblies of non-wheeled vehicles, support structures, height adjusting systems and actuators associated with industrial machinery, components thereof and / or other such equipment. Accordingly, the subject matter of the present disclosure is not intended to be limited to use associated with gas spring suspension systems of wheeled vehicles.

[0003] Wheeled motor vehicles of most types and kinds include a sprung mass, such as a body or chassis, for example, and an unsprung mass, such as two or more axles or other wheel-engaging members, for example, with a suspension system disposed therebetween. Typically, a suspension system will include a plurality of spring devices as well as a plurality of damping devices that together permit the sprung and unsprung masses of the vehicle to move in a somewhat controlled manner relative to one another. Movement of the sprung and unsprung masses toward one another is normally referred to in the art as jounce motion while movement of the sprung and unsprung masses away from one another is commonly referred to in the art as rebound motion.

[0004] It will be appreciated that vehicle suspension systems of a wide variety of types and kinds have been developed and are commonly used. Components of such vehicle suspension systems are often secured between opposing structural members that moverelative to one another during travel between jounce and rebound conditions. In some cases, the spring devices can take the form of gas spring assemblies that utilize pressurized gas as the working medium. Gas spring assemblies of various types, kinds and constructions are well known and commonly used. Typical gas spring assemblies can include a flexible wall that is secured between comparatively rigid end members and / or end member assemblies.

[0005] In many applications and uses associated with wheeled motor vehicles, the suspension system of the vehicle is adapted and arranged such that there are substantially no operating conditions, during normal usage, under which one or more of the plurality of spring devices is tensioned or otherwise undergoes tension forces, such as in cases in which the spring devices take the form of gas spring assemblies. That is, the configuration and / or use of conventional suspension systems is such that the gas spring assemblies are not tensioned under during rebound motion and are generally used in compression under normal operating conditions.

[0006] In some cases, however, the suspension system of vehicles can be constructed or otherwise configured in a manner that will allow the spring devices (e.g., gas spring assemblies) to experience conditions under which the spring devices are extended beyond a typical or normal condition of use. Such over-extended conditions are generally deemed to be undesirable. As such, a variety of arrangements have been proposed to prevent the occurrence of such conditions or to at least reduce the effect that such an event has on the structure and performance of the spring devices. However, known travelrestraint devices can undesirably increase the weight associated with the overall suspension system. Additionally, in situations in which the gas spring assemblies are utilized, known travel-restraint devices can undesirably reduce the internal volume and, thus, the spring rate of the gas spring assemblies.

[0007] Notwithstanding the common use and overall success of known travel-restraint or rebound-limiting devices, it is believed desirable to develop constructions for use in connection with gas spring assemblies and / or components thereof that are capable of providing improved performance or other characteristics and / or overcoming disadvantages of known constructions while promoting relatively low costs of manufacture, ease of assembly and / or otherwise advancing the art of gas spring devices.BRIEF DESCRIPTION

[0008] One example of a gas spring assembly in accordance with the subject matter of the present disclosure can have a longitudinal axis and include first and second end members. The gas spring assembly can also include a first flexible annular member secured between the first and second end members to at least partially define a spring chamber therebetween. The first flexible annular member has a first maximum extensible length. A second flexible annular member is disposed within the spring chamber and secured between the first and second end members. The second flexible annular member has a second maximum extensible length that is less than the first maximum extensible length of the first flexible annular member. Upon displacement of the first and second end members away from one another during extension of the gas spring assembly, the second flexible annular member reaching the second maximum extensible length prior to the first flexible annular member reaching the first maximum extensible length and thereby substantially inhibiting the first flexible annular member from reaching the first maximum extensible length.

[0009] Another example of a gas spring assembly in accordance with the subject matter of the present disclosure can have a longitudinal axis and include first and second end members. The gas spring assembly can also include a first flexible annular member secured between the first and second end members at least partially defining a spring chamber therebetween. A second flexible annular member can be disposed within the spring chamber and secured between the first and second end members. The second flexible annular member separates the spring chamber into an inner chamber portion disposed within the second flexible annular member and an outer chamber portion disposed between the first and second flexible annular members. The inner and outer chamber portions of the spring chamber are disposed in fluid communication with one another such that: the inner and outer chamber portions act as a single substantially- contiguous spring chamber during at least static conditions of use of the gas spring assembly; and fluid flow between the inner and outer chamber portions at least during dynamic conditions of use of the gas spring assembly generates pressurized gas damping.

[0010] One example of a suspension system in accordance with the subject matter of the present disclosure can include a pressurized gas system including a pressurized gas source and a control device in fluid communication with the pressurized gas source. At least one gas spring assembly in accordance with either one of the foregoing paragraphs can be disposed in fluid communication with the pressurized gas source through the control device.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] FIG. 1 is a schematic representation of one example of a suspension system that includes a plurality of gas spring assemblies in accordance with the subject matter of the present disclosure.

[0012] FIG. 2 is a side elevation view of one example of a gas spring assembly including one example of an internal rebound-limiting assembly in accordance with the subject matter of the present disclosure.

[0013] FIG. 3 is a top plan view of the exemplary gas spring assembly shown in FIG. 2.

[0014] FIG. 4 is a cross-sectional side view of the exemplary gas spring assembly shown in FIGS. 2 and 3 taken from along line 4-4 in FIG. 3.

[0015] FIG. 5 is a side elevation view of the exemplary gas spring assembly in FIGS. 2-4 shown in an extended (or rebound) condition.

[0016] FIG. 6 is a side elevation view of the exemplary gas spring assembly in FIGS. 2-5 shown in a compressed (or jounce) condition.

[0017] FIG. 7 is a cross-sectional side view of an enlarged portion of the exemplary gas spring assembly in FIGS. 2-6 identified as Detail 7 in FIG. 4.

[0018] FIG. 8 is a cross-sectional side view of an enlarged portion of the exemplary gas spring assembly in FIGS. 2-7 identified as Detail 8 in FIG. 4.

[0019] FIG. 9 is a cross-sectional side view of a greatly enlarged portion of the exemplary gas spring assembly in FIGS. 2-8 identified as Detail 9 in FIG. 8.

[0020] FIG. 10 is a top perspective view of the exemplary end closure in FIGS. 4, 8 and 9.

[0021] FIG. 11 is a bottom perspective view of the exemplary end closure in FIGS. 4 and 8-10.DETAILED DESCRIPTION

[0022] Turning now to the drawings, it is to be understood that the showings are for purposes of illustrating examples of the subject matter of the present disclosure and that the examples shown and described herein are not intended to be limiting. Additionally, it will be appreciated that the drawings are not to scale and that portions of certain features and / or elements may be exaggerated for purpose of clarity and / or ease of understanding.

[0023] FIG. 1 illustrates one example of a suspension system 100 operatively disposed between a sprung mass, such as an associated vehicle body BDY, for example, and an unsprung mass, such as associated wheels WHL, associated axles AXL and / or associated suspension components SCP, for example, of an associated vehicle VHC. It will be appreciated that any 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 in accordance with the subject matter of the present disclosure as well as one or more damper assemblies that are operatively connected between the sprung and unsprung masses and together permit the sprung and unsprung masses of the associated vehicle to move in a somewhat controlled manner relative to one another, as discussed above.

[0024] As shown in FIG. 1 , suspension system 100 can include a plurality of gas spring assemblies 102 that are operatively connected between the sprung and unsprung masses of the vehicle. Additionally, suspension system 100 can include a plurality of damper assemblies 104 that are operatively connected between the sprung and unsprung masses of the vehicle. Depending on desired performance characteristics and / or other factors, the suspension system can include any suitable number and / or arrangement of one or more gas spring assemblies and one or more damper assemblies. For example, suspension system 100 in FIG. 1 includes four gas spring assemblies 102 and four damper assemblies 104 with one of the gas spring assemblies and one of the damper assemblies disposed toward each corner of the associated vehicle adjacent acorresponding one of associated wheels WHL. It will be appreciated, however, that other configurations and / or arrangements can alternately be used without departing from the subject matter of the present disclosure.

[0025] Furthermore, the one or more gas spring assemblies and the one or more damper assemblies can be operatively connected on, along or otherwise between the sprung and unsprung masses in any suitable manner. For example, depending on desired performance characteristics and / or other factors, the one or more gas spring assemblies can, in some cases, be provided and installed separately from the one or more damper assemblies. Additionally, or in the alternative, a gas spring assembly can, optionally, be assembled together with a damper assembly such that at least a portion of the gas spring assembly is axially coextensive with the damper assembly to form so-called gas spring and damper assemblies that can then be operatively connected on, along or otherwise between the sprung and unsprung masses as a unit. It is to be recognized and understood, however, that such an axially-coextensive construction is optional and that gas spring assemblies in accordance with the subject matter of the present disclosure (as well as the components and assemblies thereof) are not intended to be limited to use in gas spring and damper assemblies.

[0026] Suspension system 100 also includes a pressurized gas system 106 operatively associated with at least gas spring assemblies 102 for selectively supplying pressurized gas (e.g., air) thereto and selectively transferring pressurized gas therefrom. In the exemplary arrangement shown in FIG. 1 , pressurized gas system 106 includes a pressurized gas source, such as a compressor 108, for example, for generating pressurized air or other gases. A control device, such as a valve assembly 110, for example, is shown as being in communication with compressor 108 and can be of any suitable configuration or arrangement. In the exemplary embodiment shown, valve assembly 110 includes a valve block 112 with a plurality of valves 114 supported thereon. Valve assembly 110 can also, optionally, include a suitable exhaust, such as a muffler 116, for example, for venting pressurized gas from the system. Optionally, pressurized gas system 106 can also include a reservoir 118 in fluid communication with the compressor and / or valve assembly 110 and suitable for storing pressurized gas for an extended period of time (e.g., seconds, minutes, hours, weeks, days, months).

[0027] Valve assembly 110 is in communication with gas spring assemblies 102 through suitable gas transfer lines 120. As such, pressurized gas can be selectively transferred into and / or out of the gas spring assemblies through valve assembly 110 by selectively operating valves 114, such as to alter or maintain vehicle height at one or more corners of the vehicle, for example.

[0028] Suspension system 100 can also include a control system 122 that is capable of communication with any one or more systems and / or components of vehicle VHC and / or suspension system 100, such as for selective operation and / or control thereof. Control system 122 can include a controller or electronic control unit (ECU) 124 communicatively coupled with compressor 108 and / or valve assembly 110, such as through a conductor or lead 126, for example, for selective operation and control thereof, which can include supplying and exhausting pressurized gas to and / or from gas spring assemblies 102. Controller 124 can be of any suitable type, kind and / or configuration.

[0029] Control system 122 can also, optionally, include one or more sensing devices 128, such as, for example, may be operatively associated with gas spring assemblies 102 and capable of outputting or otherwise generating data, signals and / or other communications having a relation to one or more of: a height of the gas spring assemblies; a distance between other components of the vehicle; a pressure or temperature having a relation to the gas spring assemblies and / or a wheel or tire or other component associated with the gas spring assemblies; and / or an acceleration, load or other input acting on the gas spring assemblies. Sensing devices 128 can be in communication with ECU 124, which can receive the data, signals and / or other communications therefrom. The sensing devices can be in communication with ECU 124 in any suitable manner, such as through conductors or leads 130, for example. Additionally, it will be appreciated that the sensing devices can be of any suitable type, kind and / or construction and can operate using any suitable combination of one or more operating principles and / or techniques.

[0030] Having described an example of a suspension system (e.g., suspension system 100) that can include gas spring assemblies in accordance with the subject matter of the present disclosure (e.g., gas spring assemblies 102), one example of such a gas spring assembly will now be described in connection with FIGS. 2-11 . As shown therein,a gas spring assembly AS1 , such as may be suitable for use as one or more of assemblies 102 in FIG. 1 , for example, is shown as having a longitudinal axis AX (FIG. 4) and including a flexible spring member (or flexible annular member) 200. Gas spring assembly AS1 also includes an end member (or end member assembly) 300 that is secured on or along the flexible spring member such that a substantially fluid-tight connection is formed therebetween. The gas spring assembly further includes an end member (or end member assembly) 400 that is operatively connected to flexible spring member 200 opposite end member assembly 300, such as by way of an end closure (or end closure assembly) 500, for example. Flexible spring member 200 can be secured on or along the end member assemblies in a substantially fluid-tight manner such that a spring chamber 202 (FIGS. 4-9) is at least partially defined by the flexible spring member between end member assembly 300, end member assembly 400, and / or end closure assembly 500.

[0031] It will be appreciated that flexible spring member 200 can be of any suitable size, shape, construction and / or configuration. Additionally, the flexible spring member can be of any type and / or kind, such as a rolling lobe-type or convoluted bellows-type construction, for example. Flexible spring member 200 is shown in FIGS. 2-9 as including a flexible wall 204 that can be formed in any suitable manner and from any suitable material or combination of materials. For example, the flexible wall can include one or more fabric-reinforced, elastomeric plies or layers and / or one or more un-reinforced, elastomeric plies or layers. Typically, one or more fabric-reinforced, elastomeric plies and one or more un-reinforced, elastomeric plies will be used together and formed from a common elastomeric material, such as a synthetic rubber, a natural rubber or a thermoplastic elastomer. In other cases, however, a combination of two or more different materials, two or more compounds of similar materials, or two or more grades of the same material could be used.

[0032] Flexible wall 204 can extend peripherally around longitudinal axis AX and can extend in a generally longitudinal direction between opposing ends 206 and 208. Additionally, flexible wall 204 can include an outer surface 210 and an inner surface 212. The inner surface can at least partially define spring chamber 202 of gas spring assembly AS1. Flexible wall 204 can include an outer or cover ply (not identified) that at leastpartially forms outer surface 210, and can also include an inner or liner ply (not identified) that at least partially forms inner surface 212. In some cases, flexible wall 204 can further include one or more reinforcing plies (not shown) disposed between outer and inner surfaces 210 and 212. The one or more reinforcing plies can be of any suitable construction and / or configuration. For example, the one or more reinforcing plies can include one or more lengths of filament material that are at least partially embedded therein. Additionally, it will be appreciated that the one or more lengths of filament material, if provided, can be oriented in any suitable manner. As one example, the flexible wall can include at least one layer or ply with lengths of filament material oriented at one bias angle and at least one layer or ply with lengths of filament material oriented at an equal but opposite bias angle.

[0033] Flexible spring member 200 can include any feature or combination of features suitable for forming a substantially fluid-tight connection with end member assembly 300 and / or end member assembly 400. As one example, flexible spring member 200 can include a mounting bead 214 disposed along end 206 of flexible wall 204 and a mounting bead 216 disposed along end 208 of the flexible wall. In some cases, the mounting beads, if provided, can, optionally, include a reinforcing element, such as an endless, annular bead wire 218, for example.

[0034] It will be appreciated that the end member assemblies can be of any suitable type, kind, construction and / or configuration, and can be operatively connected or otherwise secured to the flexible spring member in any suitable manner. In the exemplary arrangement shown in FIGS. 2-9, for example, end member assembly 300 is of a type commonly referred to as a bead plate and includes an end member wall 302 with a mounting wall portion 304 and an outer peripheral wall portion 306. End member assembly 300 is disposed along end 206 of flexible wall 204 with outer peripheral wall portion 306 crimped or otherwise deformed around at least a portion of mounting bead 214 such that a substantially fluid-tight seal can be formed between flexible spring member 200 and end member assembly 300. Mounting wall portion 304 can have an approximately planar outer surface portion 308 dimensioned to abuttingly engage an associated structural component (e.g., upper structural component USC). Mounting wall portion 304 can at least partially define one or more passages or openings 310 extendingthrough end member assembly 300, such as may be suitable for operatively connecting a pressurized gas line in fluid communication with assembly AS1, such as is shown in FIG. 1 , for example.

[0035] Gas spring assembly AS1 can be disposed between associated sprung and unsprung masses of an associated vehicle in any suitable manner. For example, one end member can be operatively connected to the associated sprung mass with the other end member disposed toward and operatively connected to the associated unsprung mass. As shown in FIG. 2, for example, end member assembly 300 can be secured on or along a first or upper structural (or suspension) component USC and can be secured thereto in any suitable manner. For example, one or more securement devices, such as mounting studs 312, for example, can be included along end member assembly 300. In some cases, the one or more securement devices (e.g., mounting studs 312) can project outwardly from mounting wall portion 304 of end member assembly 300 and can be secured thereon in a suitable manner, such as, for example, by way of a flowed-material joint (not shown) or a press-fit connection (not identified). Additionally, such one or more securement devices can extend through mounting holes HLS in upper structural component USC and can receive one or more threaded nuts 314 or other securement devices, for example. As an alternative to one or more of mounting studs 312, one or more threaded passages (e.g., blind passages and / or through passages) could be used in conjunction with a corresponding number of one or more threaded fasteners.

[0036] End member assembly 400 can be secured on or along a second or lower structural (or suspension) component LSC in any suitable manner. As one example, lower structural component LSC could include one or more mounting holes HLS extending therethrough. In such case, one of threaded fasteners 402 could extend through one of mounting holes HLS and threadably engage end member assembly 400 to secure the end member assembly on or along the lower structural component. It will be appreciated, however, that other configurations and / or arrangements could alternately be used.

[0037] End member assembly 400 is shown as including features associated with a type of end member commonly referred to as a piston (or a roll-off piston). It will be recognized that a wide variety of sizes, shapes, profiles and / or configurations can and have been used in forming end members of the types and kinds referred to as pistons orroll-off pistons, such as end member assembly 400, for example. As such, it will be appreciated that the exterior walls and / or wall portions of the end member assembly can be of any suitable shape, profile and / or configuration, such as may be useful to provide one or more desired performance characteristics, for example, and that the profile shown in FIGS. 2 and 4-6 is merely exemplary.

[0038] End member assembly 400 extends longitudinally between an end 404 and an end 406. End 404 is adapted to receivingly engage end 208 of flexible spring member 200 with end 406 of end member assembly 400 adapted for securement on or along an associated structural component, such as has been described above in connection with lower structural component LSC, for example. End member assembly 400 includes an end member shell (or end member body) 408, an end member core (or end member core assembly) 410, and can also, optionally, include one or more additional components and / or elements. End member shell 408 has a first or outer side wall (or side wall portion) 412 that extends generally longitudinally between first and second ends 404 and 406.

[0039] In an assembled condition and during use, a portion of flexible spring member 200 forms a rolling lobe 220 that is displaced along an outer surface portion 414 of outer side wall portion 412 as the gas spring assembly undergoes changes in overall height, such as, for example, may be due to variations in load conditions applied thereto, as is well understood by those of skill in the art. Gas spring assembly AS1 is shown in FIGS. 2 and 4 at a design or nominal height, which is represented in FIG. 2 by reference dimension DHT. Gas spring assembly AS1 is shown in FIG. 5 at an extended or rebound height, which is represented by reference dimension RHT and represents a maximum desired extended length of the gas spring assembly. Gas spring assembly AS1 is shown in FIG. 6 at a compressed or jounce height, which is represented by reference dimension JHT and represents a fully collapsed height of the gas spring assembly.

[0040] In addition to outer side wall portion 412, end member shell 408 includes an inner side wall portion 416 that is disposed radially inward of outer side wall portion 412. End member shell 408 also includes an end wall portion 418 that is oriented transverse to longitudinal axis AX and is disposed inwardly of inner side wall portion 416. In some cases, end wall portion 418 can at least partially define a closed end of the end membershell along end 404 with outer side wall portion 412 at least partially defining an open end of the end member shell along end 406.

[0041] End member shell 408 also includes an intermediate wall portion 420 that extends between and interconnects outer side wall portion 412 with inner side wall portion 416. The intermediate wall portion can have an inverted and somewhat U-shaped cross- sectional profile that forms a distal extent 422 of end member shell 408 along end 404 of the end member. Inner side wall portion 416 can, in some cases, be disposed at an acute angle relative to longitudinal axis AX such that the inner side wall portion of end member shell 408 has an inner surface portion 424 with a frustoconical shape or configuration. End wall portion 418 includes an end surface (or end surface portion) 426 that faces opposite end 406 and an end surface (or end surface portion) 428 that faces toward end 406. End wall portion 418 is axially offset from distal extent 422 in a direction toward end 406 such that end surface portion 426 together with inner surface portion 424 at least partially defines a recess 430 extending into end member shell 408 from along end 404.

[0042] End member core assembly 410 is at least partially received within or is otherwise disposed on or along the open end of end member shell 408 such that the end member core assembly and the end member shell together at least partially define an end member chamber 432 within end member assembly 400. In such an arrangement, recess 430 is disposed along end wall portion 418 and exposed outwardly along end member shell 408 with a recess opening 434 facing axially away from end member chamber 432.

[0043] It will be appreciated that end member core assembly 410 can be constructed in any suitable manner and can include any suitable number of one or more walls and / or wall portions. Additionally, it will be appreciated that end member shell 408 and end member core assembly 410 can be secured to one another in any manner or arrangement suitable for forming a substantially fluid-tight connection therebetween. In such an arrangement, end member chamber 432 is substantially fluidically isolated from an external atmosphere ATM of gas spring assembly AS1.

[0044] As one non-limiting example, end member core assembly 410 can include a core base wall (or core base wall portion) 436 that is oriented transverse to longitudinal axis AX and is secured on or along end member shell 408 toward end 406 of end memberassembly 400. It will be appreciated that core base wall 436 of end member core assembly 410 can be secured on or along end member shell 408 in any suitable manner. As one non-limiting example, an outer peripheral edge 438 of core base wall 436 can be attached to outer side wall portion 412 in a suitable manner, such as by way of a flowed- material joint 440, for example. Core base wall 436 can include a first or inner surface (or surface portion) 442 facing toward end member chamber 432. Core base wall 436 can also include a second or outer surface (or surface portion) 444 facing opposite inner surface 442 and dimensioned to abuttingly engage second or lower structural component LSC. Core base wall 436 can also include mounting holes 446 extending therethrough with a securement device 448 (e.g., a threaded insert) secured on or along core base wall 436 in communication with mounting holes 446 in a suitable manner, such as by flowed- material joints 450, for example.

[0045] End member core assembly 410 also includes a support column wall 452 extending from along core base wall 436 toward end 404 of the end member assembly, such as to assist in carrying forces and / or loads from end wall portion 418 to core base wall 436, for example. In some cases, support column wall 452 can be configured to at least partially define a column cavity 454 within the support column. In such cases, support column wall 452 can, optionally, include one or more openings or passages 456 extending through the support column wall such that column cavity 454 is in fluid communication with end member chamber 432 through openings 456, such as to permit the portions of end member chamber 432 inside and outside of support column wall 452 to fluidically operate as a substantially-contiguous volume.

[0046] End member core assembly 410 can include an inner end wall (or inner end wall portion) 458 disposed within end member chamber 432 and supported on or along support column wall 452. If included, inner end wall portion 458 can be oriented transverse to longitudinal axis AX and can include an end surface portion 460 disposed in abutting engagement with end surface portion 428 of end wall portion 418. It will be appreciated that inner end wall 458, if included, can be secured or otherwise provided on or along support column wall 452 in any suitable manner. As non-limiting examples, inner end wall portion 458 could be integrally formed with the support column wall or inner endwall portion 458 could be provided separately and secured to support column wall 452, such as by way of a flowed-material joint 462.

[0047] End closure assembly 500 is shown in FIG. 4 as including an end closure body 502 and is operatively secured on or along end 404 of end member assembly 400. As such, in some cases, end closure assembly 500 can be considered or otherwise deemed to be part of end member assembly 400. End closure body 502 includes an end closure wall 504 that extends around and radially outward from axis AX in transverse relation thereto. End closure wall 504 includes a surface (or surface portion) 506 disposed along one side of end closure body 502 and a surface (or surface portion) 508 disposed along another side of end closure body 502. In a preferred arrangement, surface portion 506 can be approximately planar. Surface portion 508 can be disposed toward and dimensioned to abuttingly engage end wall portion 418 of end member shell 408. End closure wall 504 also includes an outer peripheral surface portion 510 that faces radially outward and extends axially between surface portions 506 and 508. In some cases, end closure wall 504 can include or otherwise at least partially define a bead seat 512 that can extend annularly around end closure body 502 and can be dimensioned to at least partially receive or otherwise abuttingly engage mounting bead 216 and / or bead wire 218 of flexible spring member 200.

[0048] It will be appreciated that outer peripheral surface portion 512 can be of any suitable size, shape and / or configuration. For example, the outer peripheral surface portion can have a cross-sectional profile with any suitable number of linear and / or curved profile segments. In an assembled condition, end closure assembly 500 is operatively engaged with a portion of flexible spring member 200 (e.g., mounting bead 216), such as on or along outer peripheral surface portion 512, for example.

[0049] End closure assembly 500 can be secured on or along end member assembly 400 in any manner suitable for compressively capturing a portion of flexible spring member 200 (e.g., mounting bead 216) in abutting engagement between outer peripheral surface portion 512 and inner surface portion 424 of inner side wall portion 416 of end member shell 408. As a non-limiting example, a securement device 464 (e.g., threaded fastener) can extend through and thereby secure end closure assembly 500 on or along end member assembly 400. In such an example, end closure wall 504 can include a holeor passage 514 extending through end closure body 502. Additionally, end wall portion 418 can also include a hole or passage 466 extending therethrough that is cooperative with hole 514. Securement device 464 can extend through hole 514 in the end closure wall, through hole 466 in end wall portion 418 and into engagement with a corresponding securement device 468 (e.g., a threaded passage) of inner end wall portion 458. It will be appreciated, however, that other configurations and / or securement arrangements can alternately be used without departing from the subject matter of the present disclosure.

[0050] In some cases, spring chamber 202 can be disposed in fluid communication with end member chamber 432 such that gas transfer between the spring chamber and the end member chamber can generate pressurized gas damping during extension and / or compression of the gas spring assembly as the same undergoes dynamic use in operation. As a non-limiting example spring chamber 202 and end member chamber 432 can fluidically communicate with one another through end closure assembly 500, such as is discussed in greater detail hereinafter.

[0051] In some cases, gas spring assembly AS1 can include one or more fluid communication passages fluidically connected between the spring chamber and one or more end member chambers of the gas spring assembly (e.g., end member chamber 432). Generally, the one or more fluid communication passages can be dimensioned such that pressurized gas flows into, out of, through and / or is otherwise displaced within the fluid communication passage or passages.

[0052] In some cases, one or more of the fluid communication passages can be configured, constructed and / or otherwise dimensioned such that the pressurized gas flow moving therethrough can generate pressurized gas damping of vibrations and / or other dynamic inputs acting on the overall assembly and / or system. In such cases, such one or more fluid communication passages may be referred to herein as gas damping passages or, in some cases, elongated gas damping passages. In operation, differential pressure between the spring chamber and the one or more end member chambers induces gas flow along at least a portion of the length of the one or more gas damping passage(s). It will be appreciated that such movement of the pressurized gas within and / or through such a gas damping passage can act to dissipate kinetic energy acting on the assembly and / or system. In a preferred arrangement, such pressurized gas dampingcan be configured for or otherwise targeted to dissipate vibrations and / or other dynamic inputs having a particular, predetermined natural frequency or within a particular, predetermine range of frequencies.

[0053] For example, end closure body 502 can include an opening or port 516 that extends into end closure wall 504 and is accessible from along surface portion 506. End wall portion 418 includes an opening or port 470 that extends through the end wall portion and is positioned to fluidically communicate with one or more features of end closure body 502 in an assembled condition. End closure body 502 includes a passage 518 at least partially formed within end closure wall 504. In a preferred arrangement, passage 518 extends from a first end 520 disposed in fluid communication with opening 516 of the end closure body to a second end 522 disposed in fluid communication with opening 470 in end wall portion 418.

[0054] End closure wall 504 can include a passage surface 524 that at least partially defines passage 518. It will be appreciated that passage surface 524 can have any suitable cross-sectional shape and / or profile. Passage 518 is shown as having a spirallike configuration, such as may be generated by substantially-continuously rotating the cross-sectional profile of passage surface 524 about axis AX with the cross-sectional profile substantially-continuously displaced radially outward from adjacent axis AX to form the spiral-like configuration. In a preferred arrangement, such rotation of the cross- sectional profile of passage surface 524 can occur in an approximately single plane such that the spiral-like configuration of passage 518 is disposed in a common plane that is oriented transverse to longitudinal axis AX.

[0055] In some cases, the cross-sectional profile of passage surface 524 can be open (i.e., not fully enclosed). In such cases, passage 518 can be open along one or more surface portions (e.g., surface portion 508) of end closure body 502. For example, the cross-sectional profile of passage surface 524 is shown as having an approximately II- shaped cross-sectional configuration. As such, passage 518 is formed within end closure body 502 as an open channel that is accessible from along surface portion 508. In cases in which the cross-sectional profile of passage surface 524 is open or otherwise not fully enclosed, end wall portion 418 extends across surface portion 508 to substantially inhibit or at least reduce pressurized gas transfer between adjacent rings or other sections ofpassage 518 along surface portion 508. In some cases, passage 518 can be configured, constructed and / or otherwise dimensioned to provide pressurized gas damping of approximately a desired or target frequency or otherwise within a desired or targeted range of frequencies. In such cases, passage 518 can be alternately referred to herein as a gas damping passage or an elongated gas damping passage. As a non-limiting example, such a targeted frequency range can include inputs within a range of from approximately 8 Hz to approximately 15 Hz.

[0056] End closure wall 504 of end closure body 502 also includes a mounting wall (or mounting wall portion) 526 that extends in a generally axial direction from along surface portion 506 of the end closure wall toward a distal edge 528. Mounting wall portion 526 can include one or more inner surfaces (or inner surface portions) 530 that can at least partially form an end closure recess 532 extending into the end closure body. Mounting wall portion 526 can also include an outer surface 534 that can include one or more outer surface portions and can be dimensioned to receive and retain an end of a travel-limiting device, such as is described hereinafter. In some cases, one or more projections can extend radially outward from along outer surface 534, such as may be useful to retain or assist in retaining the end of the travel-limiting device on or along mounting wall 526. In the arrangement shown, a bead retaining wall (or wall portion) 536 extends radially outward beyond outer surface 534 and peripherally around axis AX.

[0057] In a preferred arrangement, end closure wall 504 includes one or more notches or slots 538 that extend into at least mounting wall portion 526. In the arrangement shown in FIGS. 4 and 8-10, notches 538 are disposed opposite one another and separate outer surface 534 into at least outer surface portions 534A and 534B. Additionally, notches 538 separate bead retaining wall 536 into at least bead retaining wall portions 536A and 536B. It will be appreciated that any suitable number of one or more notches can be included, such as from two (2) to sixteen (16) notches, for example, with the notches separating the outer surface and bead retaining wall into a corresponding number of two or more surface portions and / or wall portions.

[0058] In some cases, end closure body 502 can also include a passage 540 extending through end closure wall 504 that is separate and fluidically distinct from passage 518. In a preferred arrangement, passage 540 can extend from along surfaceportion 506 through the end closure wall to surface portion 508. In some cases, a passage wall (or passage wall portion) 542 can project or otherwise extend axially beyond surface portion 508 toward a distal end wall portion 544. In some cases, distal end wall portion 544 can at least partially define a damping orifice 546 dimensioned to control or otherwise establish pressurized gas damping on, along or otherwise through passage 540. In such cases, damping orifice 546 will have a reduced cross-sectional dimension (e.g., diameter) relative to the cross-sectional dimension (e.g., diameter) of passage 540. In some cases, damping orifice 546 can be dimensioned to provide gas damping of approximately a desired or target frequency or otherwise within a desired or targeted frequency range. In such cases, passage 540 can be alternately referred to herein as a gas damping passage. As a non-limiting example, such a targeted frequency range can include inputs within a range of from approximately 0.5 Hz to approximately 2 Hz.

[0059] In accordance with the subject matter of the present disclosure, gas spring assembly AS1 includes a travel-limiting assembly 600 that is operatively connected on, along and / or otherwise between end member assembly 300 and end member assembly 400. It will be appreciated that such a travel-limiting assembly can be operatively connected therebetween in any suitable manner (either directly or indirectly) using any combination of features, components and / or devices. Travel-limiting assembly 600 is operative to provide resistance to the extension of gas spring assembly AS1 as the gas spring assembly is extended beyond a predetermined height, such as rebound height RHT, for example. In a preferred arrangement, the travel-limiting assembly can take the form of a construction that provides minimal resistance to extension during normal use in operation but substantially inhibits extension of the gas spring assembly beyond the predetermined extended height.

[0060] As one example of a suitable construction, travel-limiting assembly 600 can include a flexible annular member 602 that is used as the working device that compresses or otherwise collapses within spring chamber 202 during jounce motion while substantially restricting rebound motion to a predetermined maximum travel distance. It will be appreciated that flexible annular member 602 can be of any suitable size, shape, construction and / or configuration. In a preferred arrangement, flexible annular member 602 can have an overall construction substantially similar to a type and kind of flexiblespring member commonly referred to as a convoluted or bellows-type construction, and it will be appreciated that any suitable type or kind of convoluted spring construction can be used. As such, in some cases, the flexible annular member can, optionally, include zero or more girdle wall portions disposed on or along flexible annular member 602. In cases in which one or more girdle wall portions are included, the one or more girdle wall portions can be spaced apart from the ends of the flexible annular member to form a corresponding number of two or more convoluted wall portions.

[0061] As a non-limiting example, flexible annular member 602 can include a flexible wall 604 that is at least partially formed from one or more layers or plies of elastomeric material (e.g., natural rubber, synthetic rubber and / or thermoplastic elastomer) and can optionally include one or more plies or layers of filament reinforcing material. Flexible wall 604 is shown extending in a longitudinal direction between opposing ends 606 and 608. In some cases, flexible wall 604 can, optionally, include a mounting bead disposed along either one or both of ends 606 and 608. In the arrangement shown in FIGS. 4-9, flexible wall 604 includes mounting beads 610 and 612 respectively disposed along ends 606 and 608. In some cases, the mounting beads can, optionally, include a reinforcing device, such as an endless, annular bead core 614, for example.

[0062] In the exemplary arrangement shown in FIGS. 2-9, flexible wall 604 of flexible annular member 602, optionally, includes a girdle wall portion 616 disposed approximately midway along flexible wall 604 between ends 606 and 608. In such a construction, a convoluted wall portion 618 extends between girdle wall portion 616 and mounting bead 610, and a convoluted wall portion 620 extends between the girdle wall portion and mounting bead 612. In some cases, girdle wall portion 616 can, optionally, include a reinforcing device, such as an endless, annular girdle hoop 622, for example. If included, girdle hoop 622 can be at least partially embedded within girdle wall portion 616 of flexible wall 604, and can function to retard or otherwise inhibit radially-outward expansion of the flexible wall during use.

[0063] As indicated above, flexible wall 604 of flexible annular member 602 can be formed in any suitable manner and from any suitable material or combination of materials, such as by using one or more fabric-reinforced, elastomeric plies or layers and / or one or more un-reinforced, elastomeric plies or layers, for example. Typically, one or more fabric-reinforced, elastomeric plies and one or more un-reinforced, elastomeric plies will be used together and formed from a common elastomeric material, such as a synthetic rubber, a natural rubber or a thermoplastic elastomer. In other cases, however, a combination of two or more different materials, two or more compounds of similar materials, or two or more grades of the same material could be used.

[0064] Flexible wall 604 can include an inner surface 624 and an outer surface 626 that each extend longitudinally along the flexible wall. Inner surface 624 can at least partially define an interior chamber 628 of the flexible annular member 602 that is disposed inwardly of the flexible wall. In a preferred arrangement, flexible wall 604 can include one or more layers or reinforcing plies disposed between inner and outer surfaces 624 and 626. The one or more reinforcing plies can be of any suitable construction and / or configuration. For example, the one or more reinforcing plies can include one or more lengths of filament material that are at least partially embedded therein. It will be appreciated that the one or more lengths of filament material can be of any suitable type, kind and / or construction, such as monofilament polymeric strands, braided cotton yarn or bundled carbon fibers, for example. Furthermore, such one or more lengths of filament material could optionally be coated or otherwise treated, such as, for example, to improve adhesion with the adjacent plies or other surrounding material. For example, the filament material could be rubber coated, such that upon applying a layer of rubber over the filament material improved adhesion between the various layers could result during and / or after vulcanization, for example.

[0065] Additionally, it will be appreciated that the one or more lengths of filament material, if provided, can be oriented in any suitable manner. As one example, flexible wall 604 is shown in FIG. 4 as including a plurality of filament segments 630A disposed at one bias angle BA1 and at least partially forming one reinforcing layer or ply 632A. Flexible wall 604 also includes a plurality of filament segments 630B disposed at another bias angle BA2 and at least partially forming another reinforcing layer or ply 632B. It will be appreciated that any suitable bias angles can be used, such as bias angles within a range of from approximately 3 degrees to approximately 87 degrees, for example. In some cases, the filament segments can be disposed at approximately the same biasangle but oriented in the opposing direction, such as is represented in FIG. 4 by reference dimensions BA1 and BA2, for example.

[0066] In accordance with the subject matter of the present disclosure, travel-limiting assembly 600 extends and collapses without generating any substantial resistance to motion as gas spring assembly AS1 is axially displaced during use toward, from and / or otherwise between a full jounce condition (i.e., fully compressed) and a full rebound condition (i.e., fully extended). Flexible annular member 602 is axially coextensive with flexible annular member 200. Upon reaching full rebound height RHT, flexible wall 604 of flexible annular member 602 becomes tensioned between end member assembly 300 and end member assembly 400 (or end closure 500, which is secured to end member assembly 400), such as is shown in FIG. 5. Though flexible wall 604 is at least partially formed from elastomeric material, the flexible wall and any filament segments embedded therein (e.g., filament segments 630A and 630B of reinforcing plies 632A and 632B) eventually reach a point of maximum elongation. In such a condition, flexible wall 604 becomes substantially inextensible in the axial direction and thereby limits extension of gas spring assembly AS1 beyond rebound height RHT, such as is shown in FIG. 5, for example.

[0067] That is, it will be appreciated that flexible annular member 200 will have a maximum extensible length associated with the dimensions and construction thereof. As such, flexible annular member 200 be capable of undergoing a maximum extension under full rebound conditions. Similarly, flexible annular member 602 will have a maximum extensible length associated with the dimensions and construction thereof. In accordance with the subject matter of the present disclosure, the maximum extensible length of flexible annular member 602 is less than the maximum extensible length of flexible annular member 200. Upon reaching a condition in which flexible annular member 602 is substantially inextensible in the axial direction, flexible annular member 200 has a greater maximum extensible length and, thus, is protected from overextension by flexible annular member 602 reaching the corresponding maximum extensible length thereof.

[0068] As gas spring assembly AS1 is compressed toward full jounce height JHT, convoluted wall portions 618 and 620 of flexible wall 604 collapse radially inward and axially into engagement one another within spring chamber 202. In such an arrangement,flexible annular member 602 remains contained within spring chamber 202, such as without flexible wall 604 substantially contacting flexible spring member 200, for example. Mounting bead 610, mounting bead 612 and girdle wall portion 616, if included, can have cross-sectional dimensions across flexible wall 604, such as are respectively represented by reference dimensions CD1 , CD2 and CD3 in FIG. 6, for example. In a preferred arrangement, cross-sectional dimension CD1 of mounting bead 610 is greater than cross- sectional dimension CD2 of mounting bead 612. In some cases, mounting bead 610, mounting bead 612 and girdle wall portion 616, if included, can respectively have cross- sectional dimensions CD1-CD3 corresponding to the relationship:CD1 > CD3 > CD2 with cross-sectional dimension CD1 being greater than cross-sectional dimension CD2 and cross-sectional dimension CD3 being less than cross-sectional dimension CD1 but greater than or approximately equal to cross-sectional dimension CD2. In a more preferred arrangement, cross-sectional dimensions CD1-CD3 respectively of mounting bead 610, mounting bead 612 and girdle wall portion 616, if included, can correspond to the relationship:CD1 > CD3 > CD2 with cross-sectional dimension CD1 being greater than cross-sectional dimension CD2 and cross-sectional dimension CD3 being less than cross-sectional dimension CD1 but greater than cross-sectional dimension CD2.

[0069] It will be appreciated that mounting beads 610 and 612 can be secured on, along and / or otherwise between end member assembly 300 and end member assembly 400 or end closure assembly 500, for example. As one non-limiting example, mounting bead 610 can be operatively connected with a mounting ring 634 that is secured on or along end member assembly 300 in a suitable manner. Mounting ring 634 can take the form of an endless annular ring that extends peripherally about axis AX.

[0070] Mounting ring 634 can include a bead wall portion 636 and a flange wall portion 638 that extends radially outward from along the bead wall portion. Bead wall portion 636 extends radially inward to an inner edge 640 and flange wall portion 638 extends radially outward to an outer edge 642. Mounting ring 634 has a surface (or surface portion) 644 facing toward mounting wall portion 304 of end member wall 302 and a surface (or surfaceportion) 646 facing away from the mounting wall portion of the end member wall. Again, in a preferred arrangement, bead wall portion 636 can have a curved cross-sectional shape or configuration, such as may be dimensioned to abuttingly engage mounting bead 610 as shown in FIGS. 4 and 7, for example. In some cases, mounting bead 610 can be permanently attached (i.e., inseparable without damage, destruction or material alteration of at least one of the component parts) to bead wall portion 636, such as by way of an adhesive and / or cured material joint (e.g., vulcanization), which is represented in FIG. 7 by dashed line JT1. In such case, joint JT1 can form a substantially fluid-tight connection between mounting bead 610 and bead wall portion 636.

[0071] Additionally, in a preferred arrangement, a substantially fluid-tight seal or joint can be formed between an end surface (or end surface portion) 648 of mounting bead 610 and an inner surface portion 316 of mounting wall portion 304 of end member wall 302, such as is represented in FIG. 7 by dashed line JT2, for example. Furthermore, in such a preferred arrangement, a substantially fluid-tight seal or joint can be formed between an end surface (or end surface portion) 222 of mounting bead 214 and surface portion 646 of flange wall portion 638, such as is represented in FIG. 7 by dashed line JT3, for example. In such an arrangement, flange wall portion 638 is captured between mounting wall portion 304 of end member wall 302 and mounting bead 610 annularly around flexible annular member 602. Additionally, in such an arrangement, spring chamber 202 and interior chamber 628 of flexible annular member 602 are substantially fluidically isolated from exterior atmosphere ATM.

[0072] Flexible annular member 602 can be secured on or along end member assembly 400 in any suitable manner, such as through attachment to end closure assembly 500, for example. In the arrangement shown in FIGS. 4-6, 8 and 9, for example, mounting bead 612 is received on or along mounting wall portion 526 of end closure wall 504. An end surface (or end surface portion) 650 of mounting bead 612 is disposed on or along outer surface 534 with the mounting bead received between bead retaining wall 536 and surface portion 506 such that mounting bead 612 is secured on or along mounting wall portion 526 in a somewhat conventional manner. That is, mounting bead 612 is disposed along outer surface portions 534A and 534B beneath bead retaining wall portions 536A and 536B. However, conventional assemblies include a substantially fluid-tight seal being formed between the mounting bead and the mounting wall portion substantially-entirely around the periphery of outer surface 534. The subject construction differs from conventional assemblies in that mounting bead 612 bridges across notches 538. As such, mounting bead 612 extends peripherally between outer surface portions 534A and 534B such that passages are defined between the mounting bead and the mounting wall portion at least through notches 538 that permit fluid communication between end closure recess 532 and spring chamber 202, which passages and fluid communication is represented in FIG. 9 by arrow 652.

[0073] To eliminate inadvertent or otherwise undesirable contact between opposing portions or components thereof, a gas spring assembly can include a jounce bumper assembly disposed within the spring chamber of the gas spring assembly. The jounce bumper assembly can be supported on or along either of the end member assemblies of the gas spring assembly. As is well understood in the art, the jounce bumper prevents or otherwise at least substantially inhibits opposing portions of the gas spring assembly (or the suspension system associated therewith) from directly impacting one another. Thus, during jounce motion, an opposing component will contact the jounce bumper rather than impacting other components on or near which the jounce bumper is mounted.

[0074] Gas spring assembly AS1 includes a jounce bumper assembly 700 that is disposed within spring chamber 202. Jounce bumper assembly 700 includes a bumper body 702 and a bumper base plate 704. Jounce bumper assembly 700 can be supported on or along any combination of one or more of end member assembly 300, end member assembly 400 and / or end closure assembly 500. In a preferred arrangement, jounce bumper assembly 700 can be supported on end closure assembly 500, such as is shown in FIGS. 4-6, 8 and 9, for example. In one exemplary arrangement, securement device 464 can extend through jounce bumper assembly 700 to thereby retain the jounce bumper assembly in abutting engagement on or along an inner support wall portion 548 of end closure wall 504, for example.

[0075] Bumper body 702 can be formed from any suitable material or combination of materials and can be of any suitable size, shape, configuration and / or construction, such as may be preferred for use in a particular application. For example, bumper body 702 can be formed from a rigid thermoplastic, a thermoplastic elastomer, a natural rubbercompound, a synthetic rubber compound, or any combination of these and / or other polymeric materials. Bumper body 702 is shown as including end surfaces (or end surface portions) 706 and 708 that are spaced apart from one another in an axial direction. An outer side surface (or surface portion) 710 can extend peripherally around the jounce bumper body. In some cases, bumper body 702 can include an inner side surface (or surface portion) 712 that at least partially defines a passage 714 extending through the bumper body. In the exemplary embodiment shown, end surface portion 706 is somewhat curved or otherwise crowned and forms an outermost extent or contact surface for the jounce bumper assembly. End surface portion 708 substantially conforms to the configuration of bumper base plate 704 with outer side surface portion 710 commonly being at least partially tapered or frustoconical in shape. It will be appreciated, however, that the exterior shape and configuration of bumper body 702 is merely exemplary and that surfaces of any suitable number, size and / or shape can alternately be used.

[0076] Bumper base plate 704 includes a plate surface (or surface portion) 716 on or along which bumper body 702 is supported and a plate surface (or surface portion) 718 facing opposite plate surface 716. Bumper body 702 can be secured on or along plate surface 716 of bumper base plate 704 in any suitable manner, such as, for example, by using any combination of any one or more of mechanical fasteners or interengaging features, an adhesive substance or joint, molding or overmolding processes, vulcanizing or other cured-material joint to permanently attach (i.e., inseparable without damage, destruction or material alteration of at least one of the component parts) bumper body 702 on or along bumper base plate 704.

[0077] Bumper base plate 704 includes a base wall portion 720 that is approximately planar and includes a hole or opening 722 extending therethrough. In such an arrangement, securement device 464 can extend through passage 714 in bumper body 702 and hole 722 in bumper base plate 704 to secure jounce bumper assembly 700 on or along inner support wall portion 548 of end closure body 502, such as has been discussed above. Bumper base plate 704 also includes an outer wall portion 724 disposed radially outward of base wall portion 720 that extends toward an outer peripheral edge 726. Outer wall portion 724 can include a curved cross-sectional shape or profile that extends peripherally around bumper base plate 704. In an installed condition, outerwall portion 724 can, optionally, assist in retaining end 208 of flexible wall 204 on or along end closure body 502. For example, outer wall portion 724 can abuttingly engage inner surface 212 of the flexible wall along mounting bead 216 to compress or otherwise urge the mounting bead toward surface portion 506 such that mounting bead 216 is retained on or along mounting wall portion 526.

[0078] As discussed above, fluid communication between end closure recess 532 and spring chamber 202 is provided by passages 652 through notches 538 even though mounting bead 216 may sealingly engage outer surface portions 534A and 534B of mounting wall portion 526. However, it will be appreciated that abutting engagement of outer wall portion 724 with inner surface 212 peripherally around jounce bumper assembly 700 can form a seal or other interface therebetween that may limit fluid communication between end closure recess 532 and interior chamber 628 of flexible annular member 602. In a preferred arrangement, interior chamber 628 is disposed in fluid communication with spring chamber 202 such that the interior chamber and the spring chamber fluidically function or otherwise act as a substantially-contiguous volume under at least static conditions of use. In some cases, pressurized gas flow through passages 730 and 732 together with notches 538, as represented by arrows 652 and 654, can provide some restriction to flow and, thus, some amount of pressurized gas damping during dynamic use in operation of gas spring assembly AS1.

[0079] It will be appreciated that such fluid communication can be achieved in any suitable manner. As one non-limiting example, bumper base plate 704 can include an intermediate wall portion 728 disposed between base wall portion 720 and outer wall portion 724. Intermediate wall portion 728 can have a curved cross-sectional shape or profile oriented opposite the curved cross-sectional profile of outer wall portion 724. In such a configuration, intermediate wall portion 728 extends peripherally around bumper base plate 704 and can contribute added volume to end closure recess 532 between end closure body 502 and bumper base plate 704. Bumper body 702 can include a passage 730 extending therethrough and bumper base plate 704 can include a hole or passage 732 extending therethrough in fluid communication with passage 730. In a preferred arrangement, passages 730 and 732 can be offset radially outward of axis AX such that at least passage 732 extends through intermediate wall portion 728, as is shown in FIGS.4, 8 and 9, for example. In such an arrangement, fluid communication between end closure recess 532 and interior chamber 628 occurs through passages 730 and 732, as is represented in FIG. 9 by arrow 654. As such, spring chamber 202 and interior chamber 628 are disposed in fluid communication with one another through end closure recess 532 together with passages 652 and 654.

[0080] In some cases, bumper base plate 704 can include an inner side wall portion 734 disposed between base wall portion 720 and outer wall portion 724. Inner side wall portion 734 can extend between and operatively connect base wall portion 720 with intermediate wall portion 728, if included. Inner side wall portion 734 can have any suitable linear or curvilinear cross-sectional shape or profile and can be oriented to extend in a generally axial direction. In some cases, inner side wall portion can at least partially form a cup or bowl-shaped section 736 disposed radially inward of outer wall portion 724. In some cases, the bumper body can be disposed within the cup-shaped section and abuttingly engage the inner side wall portion under compression associated with full jounce conditions. In other cases, bumper body 702 can be disposed along bumper base plate 704 such that end surface 708 of the bumper body extends along the bumper base plate from along at least some of base wall portion 720 along and across at least some of outer wall portion 724, such as to outer peripheral edge 726, for example.

[0081] As used herein with reference to certain features, elements, components and / or structures, numerical ordinals (e.g., first, second, third, fourth, etc.) may be used to denote different singles of a plurality or otherwise identify certain features, elements, components and / or structures, and do not imply any order or sequence unless specifically defined by the claim language. Additionally, the terms “transverse,” and the like, are to be broadly interpreted. As such, the terms “transverse,” and the like, can include a wide range of relative angular orientations that include, but are not limited to, an approximately perpendicular angular orientation. Also, the terms “circumferential,” “circumferentially,” and the like, are to be broadly interpreted and can include, but are not limited to circular shapes and / or configurations. In this regard, the terms “circumferential,” “circumferentially,” and the like, can be synonymous with terms such as “peripheral,” “peripherally,” and the like.

[0082] It is to be recognized and appreciated that terms such as “can”, “may”, “might” and the like are to be interpreted as being permissive rather than required. As such, any reference to items with which terms such as “can”, “may”, “might” and the like are used shall be interpreted as being optional rather than required by the subject matter of the present disclosure unless otherwise specifically set forth herein.

[0083] Furthermore, the phrase “flowed-material joint” and the like, if used herein, are to be interpreted to include any joint or connection in which a liquid or otherwise flowable material (e.g., a melted metal or combination of melted metals) is deposited or otherwise presented between adjacent component parts and operative to form a fixed and substantially fluid-tight connection therebetween. Examples of processes that can be used to form such a flowed-material joint include, without limitation, welding processes, brazing processes and soldering processes. In such cases, one or more metal materials and / or alloys can be used to form such a flowed-material joint, in addition to any material from the component parts themselves. Another example of a process that can be used to form a flowed-material joint includes applying, depositing or otherwise presenting an adhesive between adjacent component parts that is operative to form a fixed and substantially fluid-tight connection therebetween. In such case, it will be appreciated that any suitable adhesive material or combination of materials can be used, such as one-part and / or two-part epoxies, for example.

[0084] Further still, the term “gas” is used herein to broadly refer to any gaseous or vaporous fluid. Most commonly, air is used as the working medium of gas spring devices, such as those described herein, as well as suspension systems and other components thereof. However, it will be understood that any suitable gaseous fluid could alternately be used.

[0085] It will be recognized that numerous different features and / or components are presented in the embodiments shown and described herein, and that no one embodiment may be specifically shown and described as including all such features and components. As such, it is to be understood that the subject matter of the present disclosure is intended to encompass any and all combinations of the different features and components that are shown and described herein, and, without limitation, that any suitable arrangement of features and components, in any combination, can be used. Thus it is to be distinctlyunderstood claims directed to any such combination of features and / or components, whether or not specifically embodied herein, are intended to find support in the present disclosure. To aid the Patent Office and any readers of this application and any resulting patent in interpreting the claims appended hereto, Applicant does not intend any of the appended claims or any claim elements to invoke 35 U.S.C. 112(f) unless the words “means for” or “step for” are explicitly used in the particular claim.

[0086] Thus, while the subject matter of the present disclosure has been described with reference to the foregoing embodiments and considerable emphasis has been placed herein on the structures and structural interrelationships between the component parts of the embodiments disclosed, it will be appreciated that other embodiments can be made and that many changes can be made in the embodiments illustrated and described without departing from the principles hereof. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. Accordingly, it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the subject matter of the present disclosure and not as a limitation. As such, it is intended that the subject matter of the present disclosure be construed as including all such modifications and alterations.

Claims

CLAIMS:

1. A gas spring assembly having a longitudinal axis, said gas spring assembly comprising: a first end member; a second end member; a first flexible annular member secured between said first and second end members at least partially defining a spring chamber therebetween, said first flexible annular member having a first maximum extensible length; and, a second flexible annular member disposed within said spring chamber and secured between said first and second end members, said second flexible annular member having a second maximum extensible length that is less than said first maximum extensible length of said first flexible annular member; upon displacement of said first and second end members away from one another during extension of said gas spring assembly, said second flexible annular member reaching said second maximum extensible length prior to said first flexible annular member reaching said first maximum extensible length and thereby substantially inhibiting said first flexible annular member from reaching said first maximum extensible length.

2. A gas spring assembly according to claim 1 , wherein said second flexible annular member separates said spring chamber into an inner chamber portion disposed within said second flexible annular member and an outer chamber portion disposed between said first and second flexible annular members with said inner and outer chamber portions disposed in fluid communication with one another such that said inner and outer chamber portions act as a single substantially-contiguous spring chamber under at least static conditions of use of said gas spring assembly.

3. A gas spring assembly according to either one of claims 1 and 2, wherein said inner and outer chamber portions are disposed in fluid communication with one another such that pressurized gas damping is generated therebetween at least during dynamic conditions of use of said gas spring assembly.

4. A gas spring assembly having a longitudinal axis, said gas spring assembly comprising: a first end member; a second end member; a first flexible annular member secured between said first and second end members at least partially defining a spring chamber therebetween; and, a second flexible annular member disposed within said spring chamber and secured between said first and second end members, said second flexible annular member separating said spring chamber into an inner chamber portion disposed within said second flexible annular member and an outer chamber portion disposed between said first and second flexible annular members; said inner and outer chamber portions of said spring chamber disposed in fluid communication with one another such that: said inner and outer chamber portions act as a single substantially- contiguous spring chamber during at least static conditions of use of said gas spring assembly; and, fluid flow between said inner and outer chamber portions at least during dynamic conditions of use of said gas spring assembly generates pressurized gas damping.

5. A gas spring assembly according to claim 4, wherein said first flexible annular member has a first maximum extensible length and said second flexible annular member has a second maximum extensible length that is less than said first maximum extensible length of said first flexible annular member,upon displacement of said first and second end members away from one another during extension of said gas spring assembly, said second flexible annular member reaching said second maximum extensible length prior to said first flexible annular member reaching said first maximum extensible length and thereby substantially inhibiting said first flexible annular member from reaching said first maximum extensible length.

6. A gas spring assembly according to any one of claims 1 -5, wherein, said first flexible annular member extends lengthwise between a first first end and a first second end, said second flexible annular member extends lengthwise between a second first end and a second second end, and said second flexible annular member includes a first mounting bead disposed along said second first end and a second mounting bead disposed along said second second end opposite said first mounting bead with said first mounting bead secured along said first end member and said second mounting bead secured along said second end member.

7. A gas spring assembly according to claim 6, wherein said second flexible annular member includes a mounting ring disposed along said second first end, said mounting ring extending peripherally around said first mounting bead and operatively securing said first mounting bead along said first end member.

8. A gas spring assembly according to claim 7, wherein said mounting ring includes a mounting wall portion disposed in operative engagement with said first mounting bead and a flange wall portion projecting radially outward from along said mounting wall portion toward an outer peripheral edge.

9. A gas spring assembly according to claim 8, wherein said first mounting bead and said mounting wall portion of said mounting ring are secured to one another through a substantially fluid-tight joint.

10. A gas spring assembly according to any one of claims 7-9, wherein said flange wall portion of said mounting ring is captured between said first first end of said first flexible annular member and said first end member such that a substantially fluid-tight seal is formed therebetween.

11. A gas spring assembly according to claim 10, wherein capturing said flange wall portion of said mounting ring between said first first end of said first flexible annular member and said first end member forces said first mounting bead into abutting engagement with said first end member such that a substantially fluid-tight seal is formed therebetween.

12. A gas spring assembly according to any one of claims 1 -11 , wherein said first mounting bead of said second flexible annular member has a first cross-sectional dimension and said second mounting bead of said second flexible annular member has a second cross-sectional dimension that is less than said first cross-sectional dimension.

13. A gas spring assembly according to claim 12, wherein said second flexible annular member includes a girdle wall portion disposed in axially-offset relation to said second first end and said second second end such that said girdle wall portion is positioned between said first and second mounting beads, said girdle wall portion including a girdle cross-sectional dimension that is less than said first cross-sectional dimension of said first mounting bead and greater than or equal to said second cross-sectional dimension of said second mounting bead.

14. A gas spring assembly according to claim 13, wherein said second flexible annular member includes a first convoluted wall portion extending between said first mounting bead and said girdle wall portion and a second convoluted wall portion extending between said second mounting bead and said girdle wall portion.

15. A gas spring assembly according to either one of claims 13 and 14, wherein said second flexible annular member includes a girdle hoop at least partially embedded within said girdle wall portion.

16. A gas spring assembly according to either one of claims 1 and 15, wherein in a collapsed condition of said gas spring assembly said first and second convoluted collapse against one another.

17. A gas spring assembly according to any one of claims 1 -16, wherein said second mounting bead of said second flexible annular member is secured along said second end member.

18. A gas spring assembly according to any one of claims 1 -17 further comprising an end closure secured along said second end member such that said first second end of said first flexible annular member is compressively disposed between said second end member and said end closure with that a substantially fluid-tight connection is formed therebetween.

19. A gas spring assembly according to any one of claims 1 -18, wherein said second mounting bead of said second flexible annular member is received along one of a mounting wall portion of said second end member and a mounting wall portion of an end closure supported on said second end member.

20. A gas spring assembly according to claim 19, wherein said one of said mounting wall portion of said second end member and said mounting wall portion of said end closure includes an outer peripheral surface portion along which said second mounting bead of said second flexible annular member is received and at least one slot extending into said mounting wall portion at least partially defining a fluid passage along said mounting wall portion with an open side across said outer peripheral surface portion, said fluid passage at least partially placing an inner chamber portion and an outer chamberportion of said spring chamber separated by said second flexible annular member into fluid communication with one another.21 . A gas spring assembly according to claim 20, wherein said second mounting bead abuttingly engages said outer peripheral surface portion and bridges said open side of said fluid passage.

22. A suspension system comprising: a pressurized gas system including a pressurized gas source and a control device in fluid communication with the pressurized gas source; and, at least one gas spring assembly according to any one of claims 1 -21 disposed in fluid communication with said pressurized gas source with said control device disposed in fluid communication therebetween.

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