Gas spring end members and gas spring assemblies including same

Abstract

Gas spring end members securable to mounting beads of flexible spring member for gas spring assemblies. The gas spring end members include an end member wall (316) with a mounting wall portion (318) and a connecting wall portion (328) that are formed from a common material. The mounting wall portion (318) includes opposing mounting and inner surface portions with a first nominal wall thickness (MWT) therebetween. The connecting wall portion (328) is disposed radially outward of the mounting wall portion and projects axially toward a distal edge. The connecting wall portion includes inner and outer surface portions with a second nominal wall thickness (CWT) therebetween that is at least approximately ten (10) percent less than the first nominal wall thickness of the mounting wall portion. Gas spring assemblies including one or more of such end members as well as suspension systems and methods of assembly are also included.

Description

GAS SPRING END MEMBERS AND GAS SPRING ASSEMBLIES INCLUDING SAMEBACKGROUND

[0001] The subject matter of the present disclosure broadly relates to the art of gas spring devices and, more particularly, to gas spring end members that are configured for improved securement along an end of the flexible spring member of gas spring assemblies. More specifically, such gas spring end members are constructed to be sealingly secured on or along a mounting bead disposed along the end of the flexible spring member using reduced crimping forces. Gas spring assemblies including one or more of such gas spring end members and 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 move relative 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.

[0005] Typically, gas spring assemblies include a flexible spring member that is secured between comparatively rigid end members. In such arrangements, a fluid-tight connection is formed and maintained between the elastomeric material of the flexible spring member and one or more comparatively rigid walls and / or wall portions of the end member. In many cases, the elastomeric material of the flexible spring member is compressed along one or more surfaces of the comparatively rigid end member such that a fluid-tight seal is formed therebetween. However, challenges remain in achieving a robust, fluid-tight connection with the elastomeric material while avoiding undesirable characteristics associated with overly-robustly compressing the elastomeric material.

[0006] That is, it has been recognized that forming a connection between the end member and the end of the flexible spring member that is insufficiently fluid-tight can result in reduced performance of the gas spring assembly and / or increased maintenance associated with the use thereof. Whereas, forming an overly-robust connection that highly compresses the elastomeric material of the flexible spring member can result in degradation of the elastomeric material of the flexible spring member and / or degradation of the finish or exterior surface of the end member. As such, it is believed that an ongoing need exists to meet these and / or other competing goals.

[0007] Notwithstanding the common use and overall success of known gas spring end members, it is believed desirable to develop gas spring end member constructions and / or assemblies as well as techniques for use therewith that are capable of providing improved performance or other characteristics and / or overcoming disadvantages of known constructions of flexible spring members of gas spring assemblies 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 end member in accordance with the subject matter of the present disclosure can be dimensioned for securement to an associated mounting bead of an associated flexible spring member. The gas spring end member can have a longitudinal axis and can include an end member wall with a mounting wall portion and a connecting wall portion. The mounting wall portion can be formed from a first material and can be oriented transverse to the longitudinal axis. The mounting wall portion can include a mounting surface portion that at least partially defines a mounting plane of the gas spring end member dimensioned to abuttingly engage an associated structural component. The mounting wall portion can also include an inner surface portion facing opposite the mounting surface portion with a first nominal wall thickness therebetween. The connecting wall portion is also formed from the first material. The connecting wall portion is disposed radially outward of the mounting wall portion and extends peripherally around the longitudinal axis. The connecting wall portion can project axially beyond the mounting wall portion in a direction opposite the mounting surface portion. The connecting wall portion includes inner and outer surface portions extending therealong toward a distal edge. The connecting wall portion has a second nominal wall thickness between the inner and outer surface portions that is at least approximately ten (10) percent less than the first nominal wall thickness of the mounting wall portion.

[0009] In some cases, the connecting wall portion can include a third nominal wall thickness between the inner and outer surface portions that is disposed adjacent the distal edge. If included, the third nominal wall thickness can be at least five (5) percent greater than the second nominal wall thickness.

[0010] In some cases, the end member wall can include a sealing wall portion that is formed from the first material. If included, the sealing wall portion is disposed radially outward of the mounting wall portion and operatively connects the mounting wall portion and the connecting wall portion.

[0011] In some cases, the gas spring end member can include a cover wall formed from a second material that is different from the first material. If included, the cover wall can extend along at least one of the inner and outer surface portions of the connecting wall portion of the end member wall.

[0012] One example of a gas spring assembly in accordance with the subject matter of the present disclosure can include a flexible spring member having a longitudinal axis and extending peripherally about the longitudinal axis between a first end and a second end spaced longitudinally from the first end. A gas spring end member in accordance with any one of the foregoing paragraphs can be secured across the first end of the flexible spring member such that a substantially fluid-tight connection is formed therebetween.

[0013] 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 the foregoing paragraph can be disposed in fluid communication with the pressurized gas source through the control device.

[0014] One example of a method of assembling a gas spring assembly in accordance with the subject matter of the present disclosure can include positioning a gas spring end member according to any one of foregoing paragraphs across a mounting bead of a flexible spring member. The method can also include forcing at least the connecting wall portion of the gas spring end member radially inward and around at least a portion of the mounting bead such that a substantially fluid-tight seal is formed between the flexible spring member and at least one of the end member wall and the cover wall of the gas spring end member.BRIEF DESCRIPTION OF THE DRAWINGS

[0015] FIG. 1 is a side elevation view of one example of a gas spring assembly including a gas spring end member in accordance with the subject matter of the present disclosure.

[0016] FIG. 2 is a cross-sectional side view of the gas spring assembly shown in FIG.1 taken from along line 2-2 thereof.

[0017] FIG. 3 is a greatly enlarged portion of the exemplary gas spring assembly and exemplary end member thereof in FIGS. 1 and 2 identified as Detail 3 in FIG. 2.

[0018] FIG. 4 is the greatly enlarged portion in FIG. 3 showing an alternate embodiment of the exemplary gas spring assembly and exemplary end member thereof in accordance with the subject matter of the present disclosure.

[0019] FIG. 4A illustrates an alternate construction of the greatly enlarged portion of the alternate embodiment shown in FIG. 4.

[0020] FIG. 4B illustrates another alternate construction of the greatly enlarged portion of the alternate embodiment shown in FIG. 4.

[0021] FIG. 5 is the greatly enlarged portion in FIG. 3 showing another alternate embodiment of the exemplary gas spring assembly and exemplary end member thereof in accordance with the subject matter of the present disclosure.

[0022] FIG. 5A illustrates an alternate construction of the greatly enlarged portion of the alternate embodiment shown in FIG. 5.

[0023] FIG. 5B illustrates another alternate construction of the greatly enlarged portion of the alternate embodiment shown in FIG. 5.

[0024] FIG. 6 is a graphical representation illustrating predicted forces associated with gas spring end members in accordance with the subject matter of the present disclosure in comparison with a conventional construction undergoing otherwise conventional crimping actions.

[0025] FIG. 7 is a plot illustrating predicted plastic strain of a gas spring end member in accordance with the subject matter of the present disclosure resulting from an otherwise conventional crimping action.

[0026] FIG. 8 is a plot illustrating predicted plastic strain of a conventional gas spring end member resulting from an otherwise conventional crimping action.

[0027] FIG. 9 is an exploded view of a portion of the gas spring assembly in FIGS. 1- 3 shown prior to assembly.

[0028] FIG. 10 is an exploded view of a portion of the gas spring assembly in FIGS. 4- 4B shown prior to assembly.

[0029] FIG. 11 is an exploded view of a portion of the gas spring assembly in FIGS. 5- 5B shown prior to assembly.

[0030] FIG. 12 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.DETAILED DESCRIPTION

[0031] 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.

[0032] It will be appreciated that gas spring assemblies in accordance with the subject matter of the present disclosure can be of any suitable type, kind and / or construction. As such, it will be appreciated that although gas spring assemblies of the rolling lobe-type with an elongated flexible sleeve as the flexible spring member are shown and described herein gas spring assemblies of other types and kinds can be used without departing from the subject matter of the present disclosure, such as convoluted-type springs having flexible spring members with one or more convolutions, for example. As such, it is to be recognized and appreciated that the following discussion of gas spring assemblies and flexible spring members is merely exemplary and that gas spring end members in accordance with the subject matter of the present disclosure can be used in connection with flexible spring members of any type, kind and / or construction that include at least one mounting bead.

[0033] Examples of gas spring assemblies ASM that include a gas spring end member in accordance with the subject matter of the present disclosure secured to an exemplary flexible spring member will now be described in connection with FIGS. 1-3, 4-4B, and 5- 5B together with FIGS. 9-11. With initial reference to FIGS. 1-3, gas spring assembly ASM, such as may be suitable for use as one or more of assemblies 502 as discussed hereinafter in connection with FIG. 12, for example, is shown as having a longitudinal axis AX (FIG. 2) and including a flexible spring member 100. Gas spring assembly ASM can also include one or more end members, such as an end member (or end member assembly) 200 and / or an end member (or end member assembly) 300 that is spacedlongitudinally from end member 200. Flexible spring member 100 can extend peripherally around axis AX and axially between opposing ends 102 and 104. Flexible spring member 100 can be secured on, along and / or otherwise between end members 200 and / or 300 in a substantially fluid-tight manner such that a spring chamber 106 is at least partially defined within flexible spring member 100 between ends 102 and 104.

[0034] Gas spring assembly ASM 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 FIGS. 1 and 2, for example, end member assembly 300 can be secured on or along a first or upper structural component USC, such as an associated vehicle body BDY in FIG. 12, for example, and can be secured thereon in any suitable manner. For example, one or more securement devices 302, such as mounting studs, for example, can be included along end member assembly 300. In some cases, the one or more securement devices (e.g., the mounting studs) can project outwardly from end member 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 securement devices 304, such as threaded nuts, for example. As an alternative to one or more of securement devices 302, 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.

[0035] Additionally, a fluid communication port, such as a transfer passage 306, for example, can optionally be provided to permit fluid communication with spring chamber 106, such as may be used for transferring pressurized gas into and / or out of the spring chamber, for example. In the exemplary embodiment shown, transfer passage 306 extends through at least one of securement devices 302 and is in fluid communication with spring chamber 106. It will be appreciated, however, that any other suitable fluid communication arrangement could alternately be used.

[0036] End member 200 can be secured on or along a second or lower structural component LSC, such as an associated axle AXL or an associated suspension component SCP in FIG. 12, for example, in any suitable manner. As one example, lower structural component LSC could include one or more mounting holes HLS extending therethrough. In such case, a securement device 202, such as a threaded fastener, for example, could extend through one of mounting holes HLS and threadably engage end member 200 or a component thereof to secure the end member on or along the lower structural component.

[0037] Flexible spring member 100 can be of any suitable size, shape, construction and / or configuration. As one example, flexible spring member 100 can include a flexible wall 108 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 spring member 100 is shown extending in a longitudinal direction between opposing ends 102 and 104. Flexible spring member 100 includes a mounting bead disposed along at least one end and can, in some cases, include a mounting bead along both of ends 102 and 104 of the flexible wall. In the arrangements shown in FIGS. 1-3, 4-4B, and 5-5B as well as FIGS. 9-11 , for example, mounting beads 110 and 112 are shown as being respectively disposed along ends 102 and 104. In some cases, the mounting beads can, optionally, include a reinforcing element 114, such as an endless, annular bead wire, for example, that is embedded within the corresponding mounting bead. Additionally, mounting beads 110 and 112 can include one or more bead sealing surfaces (or surface portions) 116 that abuttingly engage one or more corresponding features and / or components of end members 300 and / or 200, respectively. For example, the bead sealing surface portions can be dimensioned to sealingly engage a corresponding surface of end member 300 and / or end member 200, or any component parts or other surfaces of either thereof. In some cases, one or more sealing structures 118 can be disposed on or along bead sealing surfaces 116 to promote sealing engagement between the mounting bead and the corresponding end member. As one non-limiting example, sealing structures 118 can take the form of one or more annular rings or ridges having a somewhat tapered ortriangular cross-sectional shape that extend peripherally around axis AX along bead sealing surfaces 116, such as is shown in FIGS. 9-11 , for example.

[0038] It will be appreciated that the one or more end members 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 arrangement shown in FIGS. 1-3, 4-4B, 5-5B, 7 and 9-11 , for example, end member assembly 300 is of a type commonly referred to as a bead plate and is shown secured to end 102 of flexible wall 108 using a fluid-tight connection. Additionally, or in the alternative, end member 200 is shown as being of a type commonly referred to as a piston (or a roll-off piston). End member 200 has an outer surface 204 that abuttingly engages flexible spring member 100 such that a rolling lobe 120 is formed along flexible wall 108. As gas spring assembly ASM is displaced between compressed and extended conditions, rolling lobe 120 is displaced along outer surface 204 in a generally conventional manner. Additionally, it will be appreciated that the outer surface of end member 200 can have any suitable size, shape and / or configuration, such as may be useful to provide one or more desired performance characteristics of gas spring assembly ASM, for example.

[0039] For example, as identified in FIG. 2, end member 200 includes an end member body 206 and extends from along a first or upper end 208 toward a second or lower end 210 that is spaced longitudinally from end 208. Body 206 includes a longitudinally- extending outer side wall 212 that extends peripherally about axis AX and at least partially defines outer surface 204. In some cases, an end wall 214 is disposed transverse to axis AX and extends radially-inward from along a shoulder portion 216, which is disposed along the outer side wall toward end 208. In some cases, end member body 206 can also include an inner side wall 218 that extends longitudinally-outward beyond end wall 214 and peripherally about axis AX. If included, inner side wall 218 can have an outer surface 220 that is dimensioned to receive end 104 of flexible spring member 100 such that a substantially fluid-tight seal can be formed therebetween. In some cases, a retaining ridge 222 can project radially-outward from along inner side wall 218 and can extend peripherally along at least a portion thereof.

[0040] In some cases, end member body 206 can, optionally, include an inner side wall 224 that extends longitudinally-inward into the body from along end wall 214. Innerside wall 224 can terminate at a bottom wall 226 that is approximately planar and can be disposed transverse to axis AX such that inner side wall 224 and bottom wall 226 at least partially define a cavity 228 within end member body 206. In some cases, one or more bridge walls 230 can, optionally, extend between and operatively interconnect outer side wall 212 and inner side wall 224.

[0041] In some cases, end member body 206 can, optionally, include an inner support wall 232 disposed radially-inward from outer side wall 212 and can extend peripherally about axis AX. In some cases, inner support wall 232 can form a hollow column-like structure that projects from along bottom wall 226 in a longitudinal direction toward end 210. In some cases, the distal end (not numbered) of outer side wall 212 and / or the distal end (not numbered) of inner support wall 232 can at least partially define a mounting plane MP formed along end 210 of the end member body. In this manner, end member body 206 can be supported, at least in part, by outer side wall 212 and / or inner support wall 232, such as on or along an associated structural member (e.g., lower structural component LSC in FIGS. 1 and 2).

[0042] In some cases, gas spring assembly ASM can also include a jounce bumper that is supported on or along one of the end members and dimensioned to abuttingly engage the other of the end members of the gas spring assembly. In such cases, axially applied loads or forces can be transmitted from one end member to the other member through abutting engagement with the jounce bumper. As one example, gas spring assembly ASM can include a jounce bumper 234 supported on end member body 206. Jounce bumper 234 can include an outer side surface 236 that extends longitudinally between a base end surface 238 and a distal end surface 240. Base end surface 238 can be disposed in abutting engagement along bottom wall 226 of end member body 206 and secured thereto in a suitable manner, such as by way of a snap-fit engagement with a bumper mount 242 disposed on or along end member body 206, for example. In such cases, distal end surface 240 is disposed in facing relation to end member 300 and can abuttingly engage an inner surface portion 308 of end member 300 as gas spring assembly ASM undergoes full jounce conditions. Under such conditions, loads and / or forces can be reacted, communicated or otherwise transferred between end members 200 and 300 and the associated mounting structures through jounce bumper 234.

[0043] End member body 206 can also include a central wall 244 that is disposed radially-inward from inner support wall 232 and forms a post-like structure that projects from along bottom wall 226 in a direction toward end 210. In some cases, central wall 244 can terminate in approximate alignment with mounting plane MP, such as is illustrated in FIG. 2, for example. End member 200 can optionally include one or more features or components suitable for use in securing the end member on or along an associated structural component. As one example, a securement device 246, such as a threaded insert, for example, can be molded into or otherwise captured and retained within central wall 244 and can be dimensioned to receivingly engage a complementary securement device (e.g., securement device 202) for securement of the end member on or along the associate structural component (e.g., lower structural component LSC). In some cases, a longitudinally-extending passage 248 can extend into central wall 244 from along mounting plane MP such that the complementary securement device can reach and engage securement device 246 or another suitable feature.

[0044] In some cases, a height or distance sensing device 310 can be, optionally, included, such as is shown in FIG. 2, for example. It will be appreciated that such a height or distance sensing device can be supported on or along an end member (e.g., one of end members 200 and 300) in any suitable manner. As one example, height sensing device 310 can be disposed within spring chamber 106 along end member assembly 300 and can be secured thereto using suitable securement devices 312. Height sensing device 310 can be of any suitable type, kind and / or construction, such as an ultrasonic, photon-based, laser or radar sensor that transmits and receives ultrasonic, photonic and / or electromagnetic signals or waves WVS (FIG. 2), for example. Additionally, it will be appreciated that height sensing device 310 can be connected to other systems and / or components of a vehicle suspension system in any suitable manner. As shown in FIG. 2, height sensing device 310 includes a lead or connection 314 that can be used for such communication purposes, such as may correspond to or be otherwise indicated by sensing devices 528 and / or leads 530 of control system 522 in FIG. 12, for example.

[0045] Additionally, as indicated above, flexible wall 108 of flexible spring member 100 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 layersand / 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.

[0046] Flexible wall 108 can include an outer surface 122 and can also include an inner surface 124 that can at least partially define spring chamber 106. Additionally, as identified in FIGS. 3, 4-4B, and 5-5B, flexible wall 108 can include an outer or cover ply 126 that at least partially forms outer surface 122, an inner or liner ply 128 that at least partially forms inner surface 124, and one or more reinforcing plies disposed between outer and inner surfaces 122 and 124. 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 yam 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.

[0047] 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 108 is shown in FIG. 1 as including a plurality of filament segments 130A of one reinforcing ply 132A disposed at one bias angle BA1 and a plurality of filament segments 130B of another reinforcing ply 132B disposed another bias angle BA2. 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 bias angle butoriented in the opposing direction, such as is represented in FIG. 1 by reference dimensions BA1 and BA2, for example.

[0048] In accordance with the subject matter of the present disclosure, end member 300 can include an end member wall 316 with a mounting wall portion 318 oriented transverse to longitudinal axis AX. Mounting wall portion 318 can include a mounting surface portion 320 that is dimensioned to abuttingly engage an associated structural component, such as upper structural component USC, for example. Mounting wall portion 318 can also include inner surface portion 308 facing opposite mounting surface portion 320 such that the inside surface portion can, in some cases, be in fluid communication with spring chamber 106. In some cases, end member wall 316 can also, optionally, include a sealing wall portion 322 disposed radially outward of mounting wall portion 318. If included, sealing wall portion 322 extends peripherally around mounting wall portion 318, such as in the form of an annular ring or zone of the end member wall extending around longitudinal axis AX, for example. If included, sealing wall portion 322 can include a sealing surface portion 324 facing opposite mounting surface portion 320 of mounting wall portion 318. Sealing surface portion 324 can be dimensioned to sealingly engage at least bead sealing surface portion 116 and / or sealing structures 118, if optionally included therealong. Again, if included, sealing wall portion 322 can include an outer surface portion 326 facing opposite sealing surface portion 324. It is to be recognized and appreciated that, in some cases, transitions between mounting wall portion 318 and sealing wall portion 322 may be indistinguishable or the wall portions may be otherwise un-demarcated with respect to one another. As such, it will be appreciated that such wall portions are identified and described herein at least partially in relation those components with which the wall portions are assembled or otherwise operatively associated.

[0049] Additionally, in accordance with the subject matter of the present disclosure, end member wall 316 also includes a connecting wall portion 328 that extends from along sealing wall portion 322 toward a distal edge 330. Connecting wall portion 328 can include an inner surface portion 332 facing radially inward and an outer surface portion 334 facing radially outward.

[0050] In a preferred arrangement, mounting wall portion 318, connecting wall portion 328 and sealing wall portion 322, if included, of end member wall 316 are integrally formedas single component. In a more preferred arrangement, mounting wall portion 318, connecting wall portion 328 and sealing wall portion 322, if included, of end member wall 316 are unitarily formed from a single quantity of material, such as a metal (e.g., steel) material, for example. Again, as indicated above, it is to be recognized and understood that, in some cases, transitions between mounting wall portion 318, sealing wall portion 322, and / or connecting wall portion 328 may be indistinguishable or the wall portions may be otherwise un-demarcated with respect to one another. As such, it will be appreciated that such wall portions are identified and described herein at least partially in relation those components with which the wall portions are assembled or otherwise operatively associated.

[0051] In an installed condition, connecting wall portion 328 is crimped or otherwise deformed at least partially around mounting bead 110 or 112, such as is represented in FIGS. 9-11 by arrows CMP, for example. In such an arrangement, connecting wall portion 328 at least partially captures the mounting bead in the radial direction. Additionally, in such an installed condition, connecting wall portion 328 extends around (i.e., wraps around) the mounting bead such that distal edge 330 is disposed within a bead recess 134 formed between the mounting bead and flexible wall 108. In such an arrangement, connecting wall portion 328 urges bead sealing surface 116 (and any sealing structures 118 that can be optionally included thereon) of mounting bead 110 or 112 into sealing engagement with sealing surface portion 324 of sealing wall portion 322 of end member wall 316 such that a fluid-tight seal is formed and maintained therebetween, such as is represented in FIGS. 3, 4-4B, and 5-5B by dashed line 136, for example.

[0052] In accordance with one aspect of the present disclosure, an end member can include an end member wall that includes sections or areas having different thicknesses and corresponding rigidities. In this manner, the end member can include one or more wall portions with a greater thickness and corresponding higher rigidity, such as for engaging and securement on or along associated structural components (e.g., upper structural component USC). Additionally, the end member can include one or more wall portions that have a reduced thickness and corresponding reduction in rigidity. Such wall portions are capable of being crimped or otherwise deformed around a mounting bead of the associated flexible spring member during an assembly process using a reduced levelof force while generating and maintaining a desired sealing arrangement between the end member and the flexible spring member.

[0053] In accordance with the subject matter of the present disclosure, one nonlimiting example of a construction for end member 300 includes mounting wall portion 318 of end member wall 316 having a mounting wall thickness, such as is represented by reference dimension MWT. Additionally, at least some of connecting wall portion 328 has a connecting wall thickness, such as is represented by reference dimension CWT, that is less than mounting wall thickness MWT. In a preferred arrangement, connecting wall thickness CWT is at least approximately ten (10) percent less than mounting wall thickness MWT, such as within a range of from approximately ten (10) percent to approximately eighty-five (85) percent less than mounting wall thickness MWT, for example. In a more preferred arrangement, connecting wall thickness CWT is at least approximately twenty (20) percent less than mounting wall thickness MWT, such as within a range of from approximately twenty (20) percent to approximately seventy-five (75) percent less than mounting wall thickness MWT, for example. In a an even more preferred arrangement, connecting wall thickness CWT is at least approximately twenty-five (25) percent less than mounting wall thickness MWT, such as within a range of from approximately twenty-five (25) percent to approximately seventy (70) percent less than mounting wall thickness MWT, for example.

[0054] Additionally, sealing wall portion 322 has a sealing wall thickness, such as is represented by reference dimension SWT. In some cases, sealing wall thickness SWT can be approximately equal to mounting wall thickness MWT. In such cases, sealing wall portion 322 and sealing surface portion 324 thereof, which can be considered optional, may be indistinguishable from mounting wall portion 318 and inner surface portion 308 thereof with connecting wall portion 328 appearing to extend from or otherwise be operatively connected to the mounting wall portion. In other cases, sealing wall thickness SWT can be at least approximately ten (10) percent less than mounting wall thickness MWT, such as within a range of from approximately ten (10) percent to approximately eighty-five (85) percent less than mounting wall thickness MWT, for example. In still other cases, sealing wall thickness SWT can be at least approximately twenty (20) percent less than mounting wall thickness MWT, such as within a range of from approximately twenty(20) percent to approximately seventy-five (75) percent less than mounting wall thickness MWT, for example. In still further cases, sealing wall thickness SWT can be at least approximately twenty-five (25) percent less than mounting wall thickness MWT, such as within a range of from approximately twenty-five (25) percent to approximately seventy (70) percent less than mounting wall thickness MWT, for example.

[0055] As described above, it will be recognized and understood that the various wall portions of end member wall 316 can be formed from a single quantity of material having at least approximately common material properties throughout the end member wall. Accordingly, it will be appreciated that the differences in thickness of such wall portions generate or otherwise result in corresponding differences in rigidity of the various wall portions. As such, a gas spring end member in accordance with the subject matter of the present disclosure can include a thicker and, thus, more rigid mounting wall portion as well as a thinner and, thus, less rigid connecting wall portion. Again, in accordance with the subject matter of the present disclosure, such constructions beneficially provide a robust and rigid mounting platform while minimizing or at least reducing the crimp force required to deform or otherwise displace the connecting wall portion of the end member into engagement with the mounting bead of the flexible spring member.

[0056] In accordance with the subject matter of the present disclosure, connecting wall portion 328 can, in some cases, include a section 328A that extends axially in an uncrimped condition of the connecting wall portion from along mounting wall portion 318 and / or sealing wall portion 322. Connecting wall portion 328 can also include a section 328B that is disposed axially away from mounting wall portion 318 and / or sealing wall portion 322 toward distal edge 330. In such an arrangement, section 328A of connecting wall portion 328 is disposed between section 328B and mounting wall portion 318 and / or sealing wall portion 322. And, in such an arrangement, section 328B is disposed between section 328A and distal edge 330. In some cases, section 328B can extend to and include distal edge 330. In such arrangements, section 328A extends annularly around end member wall 316 and has connecting wall thickness CWT that is less than section 328B such that an annular groove GRV extends radially outward into connecting wall portion 328 from along inner surface portion 332, such as is shown in FIGS. 3 and 9, for example. Additionally, section 328B extends annularly around end member wall 316 and has asection wall thickness, such as is represented by reference dimension NWT in FIG. 9 that is greater than connecting wall thickness CWT. In such an arrangement, annular section 328B has an increased rigidity compared to annular section 328A.

[0057] Annular section 328B can be axially offset from mounting wall portion 318 and / or sealing wall portion 322 in an uncrimped or otherwise uninstalled condition of end member 300. In such an arrangement, annular section 328A has a section length, such as is represented in FIG. 9 by reference dimension SLT, corresponding to a width of annular groove GRV. In some cases, section length SLT (or the width of annular groove GRV) can be at least twenty (20) percent of an overall uncrimped axial length of connecting wall portion 328, such as is represented by reference dimension UAL in FIG.9. In some cases, section length SLT can be within a range of from approximately twenty (20) percent to approximately ninety-five (95) percent of overall uncrimped axial length UAL. As such an end member, in accordance with the subject matter of the present disclosure, is crimped or otherwise undergoes an action operatively connecting the end member with mounting bead 110 or 112 of flexible spring member 100, some amount of the material (e.g., elastomeric material) and / or components (e.g., fabric reinforcing plies and / or a bead reinforcing core) of the mounting bead will be forced into annular groove GRV, such as is shown in FIG. 3, for example.

[0058] Additionally, or in the alternative, in cases in which sealing wall thickness SWT is less than mounting wall thickness MWT, as discussed above, mounting wall portion 318 and sealing wall portion 322 can be arranged in any suitable axial position relative to one another. It will be appreciated that such variations in thickness and / or in relative positions can, optionally, be used in connection with the construction shown and described in FIG. 3, such as is represented by dashed line RLP in FIG. 3. As non-limiting examples, different variations of end member wall 316 are shown in FIGS. 4, 4A, 4B, and10. For example, mounting wall portion 318 and sealing wall portion 322 can be positioned such that a midplane (in the thickness direction) of the sealing wall portion is approximately coplanar with a midplane (in the thickness direction) of the mounting wall portion, such as is represented in FIG. 4 by common plane CPL. In such an arrangement, mounting surface portion 320 and inner surface portion 308 of mounting wall portion 318 are axially offset in opposing directions relative to outer surface portion 326 and sealingsurface portion 324, respectively. As another example, outer surface portion 326 of sealing wall portion 322 can be disposed approximately coplanar with mounting surface portion 320 of mounting wall portion 318, such as is represented in FIG. 4A by common plane CPL. In such an arrangement, inner surface portion 308 of mounting wall portion 318 is axially offset from sealing surface portion 324 of sealing wall portion 322. As a further example, sealing surface portion 324 of sealing wall portion 322 can be disposed approximately coplanar with inner surface portion 308 of mounting wall portion 318, such as is represented in FIG. 4B by common plane CPL. In such an arrangement, mounting surface portion 320 is axially offset from outer surface portion 326 of sealing wall portion 324

[0059] Furthermore, or as a further alternative to the foregoing constructions, end member assembly 300 can also include a cover wall 336 that extends peripherally around longitudinal axis AX, such as is shown in FIG. 5. Cover wall 336 also wraps or otherwise extends radially and / or axially along one or more surface portions of connecting wall portion 328 and / or sealing wall portion 322. In such an arrangement, cover wall 336 can at least partially cover the full periphery of the inner and / or outer surfaces of connecting wall portion 328. Additionally, or in the alternative, cover wall 336 can at least partially cover the full periphery of the inner and / or outer surfaces of sealing wall portion 322. It is to be recognized and appreciated that any one of a variety of configurations and / or constructions can be used in accordance with the subject matter of the present disclosure.

[0060] In a preferred arrangement, end member wall 316 can be formed from a first quantity of material, such as a metal (e.g., steel) material, for example. In such an arrangement, cover wall 336 is preferably formed from a second quantity of material that is different from the material of end member wall 316. For example, cover wall 336 can be at least partially formed from a polymeric material that is permanently attached (i.e., inseparable without damage, destruction or material alteration of at least one of the component parts) to one or more wall portions of the end member wall, such as by way of an adhesive joint and / or an over-molded or other flowed-material construction, for example. It will be appreciated that in such an arrangement, cover wall 336 will form an exposed surface portion on or along at least one of sealing wall portion 322 and / or connecting wall portion 328.

[0061] Depending on the configuration and / or arrangement of the wall portions (and corresponding exposed surfaces) thereof, cover wall 336 can aid in improving the sealing interface between the end member and the flexible spring member in any one or more of a variety of ways. As a non-limiting example, such an arrangement can promote sealing between an inner surface of the cover wall and the mounting bead of the flexible spring member thereby potentially permitting the use of reduced crimp forces. Additionally, or in the alternative, such an arrangement can reduce frictional engagement between an inner surface of the cover wall and an outer surface of the mounting bead thereby potentially permitting the use of reduced forces during the crimping (or other deformation) process. As a further example, or as a further alternative, such a construction can permit an outer wall portion of the cover wall to provide a protective wall or skin for one or more portions of the end member wall during the crimping (or other deformation) process while also inhibiting exposure of such portions of the end member wall in an installed condition.

[0062] As mentioned above, it will be recognized and appreciated that any one of a variety of configurations and / or constructions of end member wall 316 and cover wall 336 can be used in accordance with the subject matter of the present disclosure. As one nonlimiting example of such an arrangement, cover wall 336 can include an outer cover wall portion 338 extending along outer surface portion 334 of connecting wall portion 328 of end member wall 316. In some cases, outer cover wall portion 338 can extend along the outer surface portion of connecting wall portion 328 and along outer surface portion 326 of sealing wall portion 322, such as is illustrated in FIG. 5A, for example. In either of such cases, outer cover wall portion 338 forms an outer surface portion 340 of the end member assembly on or along connecting wall portion 328 and, optionally, along sealing wall portion 322. In some cases, cover wall 336 can also, optionally, extend around and along distal edge 330 of the connecting wall portion.

[0063] As another non-limiting example, cover wall 336 can include an inner cover wall portion 342 extending along inner surface portion 332 of connecting wall portion 328. In some cases, inner cover wall portion 342 can extend along the inner surface portion of connecting wall portion 328 and along sealing surface portion 324 of sealing wall portion 322, such as is illustrated in FIG. 5B, for example. In either of such cases, inner cover wall portion 342 forms an inner surface portion 344 of the end member assembly on oralong connecting wall portion 328 and, optionally, along sealing wall portion 322. In either or both of such cases, cover wall 336 can also, optionally, extend around and along distal edge 330 of the connecting wall portion. Additionally, in such an arrangement inner surface portion 344 can sealingly engage mounting bead 110 or 112. In some cases, inner surface portion 344 can be dimensioned to sealingly engage at least bead sealing surface portion 116 and sealing structures 118, if optionally included therealong.

[0064] In some cases, cover wall 336 can include outer cover wall portion 338 extending along outer surface portion 334 of connecting wall portion 328 and inner cover wall portion 342 extending along inner surface portion 332 of the connecting wall portion with an end wall portion 346 of cover wall 336 extending around and along distal edge 330 of connecting wall portion 328, such as is illustrated in FIGS. 5 and 11 , for example.

[0065] In an installed condition, connecting wall portion 328 and cover wall 336 extending therealong are crimped or otherwise deformed at least partially around mounting bead 110 or 112, such as is represented in FIGS. 11 by arrows CMP, for example. In such an arrangement, connecting wall portion 328 and cover wall 336 extending therealong at least partially capture the mounting bead in the radial direction. Additionally, in such an installed condition, connecting wall portion 328 and cover wall 336 extending therealong extends around (i.e., wraps around) the mounting bead such that at least distal edge 330 and end wall portion 346 are disposed within bead recess 134 formed between the mounting bead and flexible wall 108. In such an arrangement, connecting wall portion 328 and cover wall 336 extending therealong urge bead sealing surface 116 (and any sealing structures 118 that can be optionally included thereon) of mounting bead 110 or 112 into sealing engagement with a sealing surface portion (e.g., sealing surface portion 324 of sealing wall portion 322 or inner surface portion 344 of inner cover wall portion 342) of end member assembly 300 such that a fluid-tight seal is formed and maintained therebetween, such as is represented in FIGS. 5, 5A, and 5B by dashed line 136, for example.

[0066] To accommodate the inclusion of cover wall 336 while also providing sufficient strength and rigidity to end member assembly 300, end member wall 316 can include sections or areas having different thicknesses and corresponding rigidities, such as have been described above. In this manner, the end member can include one or more wallportions with a greater thickness and corresponding higher rigidity, such as for engaging and securement on or along associated structural components (e.g., upper structural component USC). Additionally, the end member can include one or more wall portions that have a reduced thickness and corresponding reduction in rigidity. Such wall portions are capable of being crimped or otherwise deformed around a mounting bead of the associated flexible spring member during an assembly process using a reduced level of force while generating and maintaining a desired sealing arrangement between the end member and the flexible spring member.

[0067] As a non-limiting example, mounting wall portion 318 of the end member wall 316 can have a mounting wall thickness, such as is represented by reference dimension MWT. Connecting wall portion 328 of the end member wall can have a connecting wall thickness, such as is represented by reference dimension CWT, that is less than mounting wall thickness MWT. In a preferred arrangement, connecting wall thickness CWT can be at least approximately five (5) percent less than mounting wall thickness MWT. In a more preferred arrangement, connecting wall thickness CWT can be at least approximately ten (10) percent less than mounting wall thickness MWT. In an even more preferred arrangement, connecting wall thickness CWT can be at least approximately twenty (20) percent less than mounting wall thickness MWT.

[0068] Additionally, sealing wall portion 322 can have a sealing wall thickness, such as is represented by reference dimension SWT. In some cases, sealing wall thickness SWT can be at least approximately five (5) percent less than mounting wall thickness MWT. In other cases, connecting wall thickness CWT can be at least ten (10) percent less than mounting wall thickness MWT. In still other cases, connecting wall thickness CWT can be at least twenty (20) percent less than mounting wall thickness MWT. In some cases, connecting wall thickness CWT and sealing wall thickness SWT can be approximately equal to one another. As described above, the various wall portions of end member wall 316 can be formed from a single quantity of material having approximately common material properties throughout the end member wall such that the differences in thickness correspond to differences in rigidity of the various wall portions.

[0069] Additionally, in some cases, cover wall 336 can have a cover wall thickness VWT that is approximately consistent and uniform along and across the various wallportions of the cover wall. In a preferred arrangement, cover wall thickness VWT can be at least approximately five (5) percent of mounting wall thickness MWT. In such an arrangement, connecting wall thickness CWT together with cover wall thickness VWT can combine to approximately equal mounting wall thickness MWT. For example, in cases in which the cover wall extends along only one side of connecting wall portion 328 (and / or sealing wall portion 322), connecting wall thickness CWT (and / or sealing wall thickness SWT) can be at least approximately five (5) percent less than mounting wall thickness MWT and cover wall thickness VWT can be at least approximately five (5) percent of mounting wall thickness MWT. As another example, in cases in which the cover wall extends along both sides of connecting wall portion 328 (and / or sealing wall portion 322), connecting wall thickness CWT (and / or sealing wall thickness SWT) can be at least approximately ten (10) percent less than mounting wall thickness MWT and cover wall thickness VWT can be at least approximately five (5) percent of mounting wall thickness MWT along each side of the connecting and / or sealing wall portions. It will be appreciated, however, that the foregoing descriptions are merely exemplary and that other values and / or arrangements could alternately be used.

[0070] In cases, in which sealing wall thickness SWT is less than mounting wall thickness MWT, as discussed above, mounting wall portion 318 and sealing wall portion 322 can be arranged in any suitable axial position relative to one another. As non-limiting examples, different variations of end member wall 316 are shown in FIGS. 5, 5A, and 5B. For example, mounting wall portion 318 and sealing wall portion 322 can be positioned such that a midplane (in the thickness direction) of the sealing wall portion is approximately coplanar with a midplane (in the thickness direction) of the mounting wall portion, such as is represented in FIG. 5 by common plane CPL. In such an arrangement, mounting surface portion 320 and inner surface portion 308 of mounting wall portion 318 are axially offset in opposing directions relative to outer surface portion 326 and sealing surface portion 324 of the sealing wall portion, respectively. In such an arrangement, inner surface portion 308 of the mounting wall portion can be approximately coplanar with inner surface portion 344 of inner cover wall portion 342 and mounting surface portion 320 can be approximately coplanar with outer surface portion 340 of outer cover wall portion 338.

[0071] As another example, outer surface portion 326 of sealing wall portion 322 can be disposed approximately coplanar with mounting surface portion 320 of mounting wall portion 318, such as is represented in FIG. 5A by common plane CPL. In such an arrangement, inner surface portion 308 of mounting wall portion 318 is axially offset from sealing surface portion 324 of sealing wall portion 322. In such an arrangement, inner surface portion 308 of the mounting wall portion can be approximately coplanar with inner surface portion 344 of inner cover wall portion 342. As a further example, sealing surface portion 324 of sealing wall portion 322 can be disposed approximately coplanar with inner surface portion 308 of mounting wall portion 318, such as is represented in FIG. 5B by common plane CPL. In such an arrangement, mounting surface portion 320 is axially offset from outer surface portion 326 of sealing wall portion 322. In such an arrangement, mounting surface portion 320 can be approximately coplanar with outer surface portion 340 of outer cover wall portion 338.

[0072] FIG. 6 is a graphical representation of predicted forces associated with an otherwise conventional process of crimping or otherwise deforming end members during assembly on or along a mounting bead of a flexible spring member. In particular, predicted forces associated with crimping or otherwise deforming a conventional bead plate are represented by line CNV. FIG. 6 also illustrates lines representing predicted forces associated with bead plate constructions in accordance with the subject matter of the present disclosure. For example, predicted forces associated with crimping or otherwise deforming end members such as those shown and described in connection with at least FIGS. 1 -3 and 9 are represented by line EM1 in FIG. 6. And, predicted forces associated with crimping or otherwise deforming end members such as those shown and described in connection with at least FIGS. 4-4B, 5-5B, 10 and 11 are represented by line EM2 in FIG. 6. As such, FIG. 6 appears to favorably illustrate that constructions in accordance with the subject matter of the present disclosure are predicted to utilize reduced levels of force to secure the subject end members to otherwise conventional mounting beads of flexible spring members using otherwise conventional processes in comparison with known bead plate constructions.

[0073] FIG. 7 illustrates predicted plastic strain within a crimped end member in accordance with the subject matter of the present disclosure, such as is shown anddescribed in connection with at least FIGS. 1-3 and 9, for example. FIG. 8 illustrates predicted plastic strain within an otherwise conventional bead plate-style end member after formation of a crimped connection. It will be appreciated that, particularly in the areas identified by reference characters A in both FIGS. 7 and 8, a bead plate-style end member in accordance with the subject matter of the present disclosure is expected to favorably have reduced plastic strain in comparison with conventional bead plate-style end members. When considered together, FIGS. 6-8 appear to illustrate that that a desirable reduction in crimp force as well as desirable decreases in plastic strain in the crimped end members can be achieved in comparison with conventional constructions.

[0074] FIG. 12 illustrates one example of a suspension system 500 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.

[0075] As shown in FIG. 12, suspension system 500 can include a plurality of gas spring assemblies 502, such as have been described herein in accordance with the subject matter of the present disclosure, that are operatively connected between the sprung and unsprung masses of the vehicle. Additionally, suspension system 500 can include a plurality of damper assemblies 504 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 500 in FIG. 12 includes four gas spring assemblies 502 and four damper assemblies 504 with one of the gas springassemblies and one of the damper assemblies disposed toward each corner of the associated vehicle adjacent a corresponding 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.

[0076] 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 that such axially-coextensive constructions, while optional, are contemplated herein and that gas spring assemblies in accordance with the subject matter of the present disclosure (as well as the components and assemblies thereof) can be used in connection with gas spring and damper assemblies.

[0077] Suspension system 500 also includes a pressurized gas system 506 operatively associated with at least gas spring assemblies 502 for selectively supplying pressurized gas (e.g., air) thereto and selectively transferring pressurized gas therefrom. In the exemplary arrangement shown in FIG. 12, pressurized gas system 506 includes a pressurized gas source, such as a compressor 508, for example, for generating pressurized air or other gases. A control device, such as a valve assembly 510, for example, is shown as being in communication with compressor 508 and can be of any suitable configuration or arrangement. In the exemplary embodiment shown, valve assembly 510 includes a valve block 512 with a plurality of valves 514 supported thereon. Valve assembly 510 can also, optionally, include a suitable exhaust, such as a muffler 516, for example, for venting pressurized gas from the system. Optionally, pressurized gas system 506 can also include a reservoir 518 in fluid communication with thecompressor and / or valve assembly 510 and suitable for storing pressurized gas for an extended period of time (e.g., seconds, minutes, hours, weeks, days, months).

[0078] Valve assembly 510 is in communication with gas spring assemblies 502 through suitable gas transfer lines 520. As such, pressurized gas can be selectively transferred into and / or out of the gas spring assemblies through valve assembly 510 by selectively operating valves 514, such as to alter or maintain vehicle height at one or more corners of the vehicle, for example.

[0079] Suspension system 500 can also include a control system 522 that is capable of communication with any one or more systems and / or components of vehicle VHC and / or suspension system 500, such as for selective operation and / or control thereof. Control system 522 can include a controller or electronic control unit (ECU) 524 communicatively coupled with compressor 508 and / or valve assembly 510, such as through a conductor or lead 526, for example, for selective operation and control thereof, which can include supplying and exhausting pressurized gas to and / or from gas spring assemblies 502. Controller 524 can be of any suitable type, kind and / or configuration.

[0080] Control system 522 can also, optionally, include one or more sensing devices 528, such as, for example, may be operatively associated with gas spring assemblies 502 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 528 can be in communication with ECU 524, which can receive the data, signals and / or other communications therefrom. The sensing devices can be in communication with ECU 524 in any suitable manner, such as through conductors or leads 530, 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.

[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 usedto 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 distinctly understood 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 end member dimensioned for securement to an associated mounting bead of an associated flexible spring member, said gas spring end member having a longitudinal axis and comprising: an end member wall including: a mounting wall portion formed from a first material, said mounting wall portion oriented transverse to said longitudinal axis, said mounting wall portion including a mounting surface portion at least partially defining a mounting plane of said gas spring end member and dimensioned to abuttingly engage an associated structural component, said mounting wall portion including an inner surface portion facing opposite said mounting surface portion with a first nominal wall thickness therebetween; and, a connecting wall portion formed from said first material, said connecting wall portion disposed radially outward of said mounting wall portion and extending peripherally around said longitudinal axis, said connecting wall portion projecting beyond said mounting wall portion in an axial direction opposite said mounting surface portion, said connecting wall portion including inner and outer surface portions extending therealong toward a distal edge, said connecting wall portion having a second nominal wall thickness between said inner and outer surface portions that is at least approximately ten (10) percent less than said first nominal wall thickness of said mounting wall portion.

2. A gas spring end member according to claim 1 , wherein said mounting wall portion and said connecting wall portion are unitarily formed from said first material.

3. A gas spring end member according to either one of claims 1 and 2, wherein said first material is a metal material having common material properties along said mounting wall portion and connecting wall portion such that said connecting wall portion has a reduced rigidity relative to said mounting wall portion due primarily to said second nominal wall thickness being at least approximately ten (10) percent less than said first nominalwall thickness with said reduced rigidity permitting a reduction in crimp force in deforming said connecting wall portion around the associated mounting bead of the associated flexible spring member.

4. A gas spring end member according to any one of claims 1-3, wherein said connecting wall portion includes a third nominal wall thickness between said inner and outer surface portions adjacent said distal edge, said third nominal wall thickness being at least five (5) percent greater than said second nominal wall thickness.

5. A gas spring end member according to claim 4, wherein said first nominal wall thickness of said mounting wall portion and said third nominal wall thickness of said connecting wall portion are approximately equal.

6. A gas spring end member according to either one of claims 4 and 5, wherein said connecting wall portion includes a first annular section having said second nominal wall thickness and a second annular section having said third nominal wall thickness such that said first annular section at least partially defines an annular groove along said connecting wall portion between said mounting wall portion and said second annular section.

7. A gas spring end member according to any one of claims 4-6, wherein said second annular section has increased rigidity relative to said first annular section due primarily to said third nominal wall thickness being at least approximately five (5) percent greater than said second nominal wall thickness.

8. A gas spring end member according to any one of claims 4-7, wherein said connecting wall portion has an uncrimped axial length and includes a first annular section having said second nominal wall thickness and a second annular section having said third nominal wall thickness with said first annular section having a first section length that is at least twenty (20) percent of said uncrimped axial length of said connecting wall portion.

9. A gas spring end member according to claim 8, wherein said second annular section has a second section length that is at least five (5) percent of said uncrimped axial length.

10. A gas spring end member according to any one of claims 1 -9, wherein said end member wall includes a sealing wall portion formed from said first material, said sealing wall portion disposed radially outward of said mounting wall portion and operatively connecting said mounting wall portion and said connecting wall portion.

11. A gas spring end member according to claim 10, wherein said sealing wall portion includes a sealing surface portion facing opposite said mounting surface portion of said mounting wall portion, said sealing wall portion being approximately planar and dimensioned to abuttingly engage an associated surface portion of the associated mounting bead of the associated flexible spring member such that a fluid-tight seal is formed therebetween12. A gas spring end member according to either one of claims 10 and 11 , wherein said sealing wall portion has a fourth nominal wall thickness that is less than said first nominal wall thickness of said mounting wall portion.

13. A gas spring end member according to claim 12, wherein said second and fourth nominal wall thicknesses are approximately equal.

14. A gas spring end member according to claim 12, wherein said third and fourth nominal wall thicknesses are approximately equal.

15. A gas spring end member according to any one of claims 10-14, wherein said mounting wall portion has a mounting wall midline extending therethrough transverse to said longitudinal axis and said sealing wall portion has a sealing wall midline extending therethrough transverse to said longitudinal axis with said mounting wall midline and said sealing wall midline disposed in a common plane.

16. A gas spring end member according to any one of claims 10-14, wherein said sealing wall portion has an outer surface portion oriented transverse to said longitudinal axis and disposed in a common plane with said mounting surface portion of said mounting wall portion.

17. A gas spring end member according to any one of claims 10-14, wherein said sealing wall portion of said sealing wall is disposed in a common plane with said inner surface portion of said mounting wall portion.

18. A gas spring end member according to any one of claims 1 -17 further comprising a cover wall formed from a second material that is different from said first material, said cover wall extending along at least one of said inner and outer surface portions of said connecting wall portion of said end member wall.

19. A gas spring end member according to claim 18, wherein said cover wall has a cover wall thickness therealong of at least approximately five (5) percent of said first nominal wall thickness of said mounting wall portion.

20. A gas spring end member according to either one of claims 18 and 19, wherein said cover wall extends along each of said inner and outer surface portions of said connecting wall portion of said end member wall.21 . A gas spring end member according to claim 20, wherein said cover wall extends around said distal edge of said connecting wall portion and operatively connects said inner and outer surface portions.

22. A gas spring end member according to any one of claims 18-21 , wherein said second nominal wall thickness between said inner and outer surface portions of said connecting wall portion is at least approximately ten (10) percent less than said first nominal wall thickness of said mounting wall portion, and said cover wall thickness is atleast approximately five (5) percent of said first nominal wall thickness of said mounting wall portion.

23. A gas spring end member according to claim 22, wherein said second nominal wall thickness between said inner and outer surface portions of said connecting wall portion is at least approximately twenty (20) percent less than said first nominal wall thickness of said mounting wall portion, and said cover wall thickness is at least approximately ten (10) percent of said first nominal wall thickness of said mounting wall portion.

24. A gas spring end member according to any one of claims 18-23, wherein said end member wall includes a sealing wall portion formed from said first material, said sealing wall portion disposed radially outward of said mounting wall portion and operatively connecting said mounting wall portion and said connecting wall portion.

25. A gas spring end member according to claim 24, wherein said sealing wall portion includes an inner surface portion facing opposite said mounting surface portion of said mounting wall portion and an outer surface portion facing opposite said inner surface portion with said cover wall extending along at least one of said inner and outer surface portions of said sealing wall portion.

26. A gas spring end member according to claim 25, wherein said cover wall extends along said inner surface portion of said sealing wall portion and includes a sealing surface portion disposed therealong dimensioned to abuttingly engage an associated surface portion of the associated mounting bead of the associated flexible spring member such that a fluid-tight seal is formed therebetween.

26. A gas spring end member according to either one of claims 25 and 26, wherein said cover wall extends along said outer surface portion of said sealing wall portion.

27. A gas spring end member according to any one of claims 24-26, wherein a fourth nominal wall thickness between said inner and outer surface portions of said sealing wall portion is at least approximately ten (10) percent less than said first nominal wall thickness of said mounting wall portion, and said cover wall thickness is at least approximately five (5) percent of said first nominal wall thickness of said mounting wall portion.

28. A gas spring end member according to claim 27, wherein said fourth nominal wall thickness between said inner and outer surface portions of said sealing wall portion is at least approximately twenty (20) percent less than said first nominal wall thickness of said mounting wall portion, and said cover wall thickness is at least approximately ten (10) percent of said first nominal wall thickness of said mounting wall portion.

29. A gas spring end member according to any one of claims 24-28, wherein said mounting wall portion has a mounting wall midline extending therethrough transverse to said longitudinal axis and said sealing wall portion has a sealing wall midline extending therethrough transverse to said longitudinal axis with said mounting wall midline and said sealing wall midline disposed in a common plane, and said cover wall extending along at least one of said inner and outer surface portions of said sealing wall portion.

30. A gas spring end member according to any one of claims 24-28, wherein said outer surface portion of said sealing wall portion is disposed in a common plane with said mounting surface portion of said mounting wall portion, and said cover wall extends along said at least said inner surface portion of said sealing wall portion.31 . A gas spring end member according to any one of claims 24-28, wherein said inner surface portion of said sealing wall portion is disposed in a common plane with said inner surface portion of said mounting wall portion, and said cover wall extends along said at least said outer surface portion of said sealing wall portion.

32. A gas spring end member according to any one of claims 18-31 , wherein said first material of said end member wall is a metal material, and said second material of said cover wall is a polymeric material.

33. A gas spring assembly comprising: a flexible spring member having a longitudinal axis and extending peripherally about said longitudinal axis between a first end and a second end spaced longitudinally from said first end; and, a gas spring end member according to any one of claims 1 -32 secured across said first end of said flexible spring member such that a substantially fluid-tight connection is formed therebetween.

34. 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 claim 33 disposed in fluid communication with said pressurized gas source with said control device disposed in fluid communication therebetween.

35. A method of assembling a gas spring assembly, said method comprising: positioning a gas spring end member according to any one of claims 1 -32 across a mounting bead of a flexible spring member; and, forcing at least said connecting wall portion of said gas spring end member radially inward and around at least a portion of said mounting bead such that a substantially fluid- tight seal is formed between said flexible spring member and at least one of said end member wall and said cover wall of said gas spring end member.

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