Patent Description:
The subject matter of the present invention 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 invention 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 invention could be used in connection with gas spring and damper 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 invention is not intended to be limited to use associated with suspension systems of wheeled vehicles.

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. Generally, the plurality of spring devices function to accommodate forces and loads associated with the operation and use of the vehicle, and the plurality of damping devices are operative to dissipate undesired inputs and movements of the vehicle, particularly during dynamic operation thereof. 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.

In some cases, the spring devices of vehicle suspension systems can be of a type and kind that are commonly referred to in the art as gas spring assemblies, which are understood to utilize pressurized gas as the working medium thereof. Typically, such gas spring assemblies include a flexible spring member that is operatively connected between comparatively rigid end members to form a spring chamber. Pressurized gas can be transferred into and/or out of the spring chamber to alter the height of the gas spring assembly, the position of the sprung and unsprung masses relative to one another and/or to provide other performance-related characteristics. Vehicle suspension systems also commonly include one or more dampers or damping components that are operative to dissipate energy associated with undesired inputs and movements of the sprung mass, such as road inputs occurring under dynamic operation of a vehicle, for example. Such dampers often contain a quantity of damping liquid and are typically operatively connected between a sprung mass and an unsprung mass, such as between a body and axle of a vehicle, for example. In some cases, the gas spring and damper can be operatively connected with one another to form a gas spring and damper assembly with a portion of the damper extending through the spring chamber of the gas spring.

Additionally, a variety of sensor arrangements, control devices and/or other electronic components are commonly used to assist in monitoring and/or altering the performance and/or operation of the suspension components, such as one or more spring devices, damping devices and/or any combination thereof. As non-limiting examples, such sensors can include any number of zero or more height sensors, acceleration sensors, gyroscopic sensors, pressure sensors, and/or temperature sensors. Additionally, or in the alternative, non-limiting examples of such control devices can include valves operable to transfer pressurized gas into and/or out of one or more gas spring devices and/or chambers thereof and/or values operable to alter performance characteristics of one or more damping devices. In many cases, electrical power and communications are transferred into and/or out of such one or more sensor arrangements, control devices and/or other electrical components by way of wires and/or other conductors, and a variety of constructions have been developed to allow such wires and/or other conductors to pass into and out of the spring chamber while maintaining a substantially fluid-tight connection with the gas spring.

Notwithstanding the overall success of known constructions, certain disadvantages may still exist that could be limiting to broader adoption and/or use of gas spring and damper assemblies with internal sensors, control devices and/or other electronic components. Accordingly, it is believed desirable to develop constructions that overcome the foregoing and/or other problems and/or disadvantages of known designs, and/or otherwise advance the art of gas spring and damper assemblies. Gas springs and related components according to the prior art are known, for instance, from documents <CIT>, <CIT>, <CIT>, <CIT>.

One example of a seal cap can be dimensioned for securement to an associated end member of an associated gas spring and damper assembly. The seal cap can include a seal cap body having a longitudinal axis and extending outward from along the longitudinal axis toward an outer periphery dimensioned to cooperatively engage the associated end member. The seal cap body can include a first surface portion disposed along a first side of the seal cap and a second surface portion disposed along a second side of the seal cap and facing opposite the first surface portion. The seal cap body can also include an outer peripheral surface portion that can at least partially define the outer periphery of the seal cap. An electrical conductor can be at least partially embedded within the seal cap body such that a substantially fluid tight seal is formed along at least a portion of the electrical conductor while remaining conductively accessible along the first side, the second side or the first and second sides of the seal cap.

In some cases, a seal cap according to the foregoing paragraph can have an electrical conductor that includes an embedded conductor portion that is at least partially embedded within the seal cap body and an outer conductor portion conductively coupled with the embedded conductor portion. The outer conductor portion can project outwardly beyond one of the first surface portion, the second surface portion and the outer peripheral surface portion.

In some cases, a seal cap according to the foregoing paragraph can include an electrical conductor for which the outer conductor portion is a first outer conductor portion projecting outward beyond one of the first surface portion and the outer peripheral surface portion. And, the electrical conductor can include a second conductor portion projecting outward beyond one of the second surface portion and the outer peripheral surface portion.

In some cases, a seal cap according to any one of foregoing three paragraphs can include a portion of the solid electrical conductor extending longitudinally beyond the first end surface portion in the direction opposite the second end surface portion with the portion of the electrical conductor being adapted for insertion into an associated electrical connector.

Another example of a gas spring seal cap can be dimensioned for securement to an associated end member. The gas spring seal cap can include a seal cap body having a longitudinal axis and extending radially outward from along the longitudinal axis. The seal cap body can include a first end surface portion disposed along a first side of the gas spring seal cap and a second end surface portion disposed along a second side of the gas spring seal cap that is spaced longitudinally from the first side and facing opposite the first end surface portion with an outer peripheral surface portion disposed between the first and second end surface portions. The gas spring seal cap can also include a first electrical conductor and a second electrical conductor that each extend through the seal cap body with each of the first and second electrical conductors disposed radially inward from the outer peripheral surface of the seal cap body. The first and second electrical conductors can include a first terminal end conductively accessible from along the first end surface portion of the seal cap body and a second terminal end conductively accessible from along the second end surface portion of the seal cap body. The first and second terminal ends can be adapted for conductive coupling with associated electrical connectors. Each of the first and second electrical conductors can include a substantially impermeable portion having a substantially fluid-tight connection with the seal cap body. The substantially impermeable portion of each of the first and second electrical conductors can substantially inhibit fluid communication across the seal cap body through a respective one of the first and second electrical conductors.

An example of a gas spring and damper assembly can include a damper that can include a damper housing and a damper rod operatively connected with the damper housing for relative reciprocal motion therebetween. A gas spring having a longitudinal axis can include a first end member supported on the damper rod and a second end member longitudinally spaced from the first end member with the second end member extending longitudinally along at least a portion of the damper housing. A flexible spring member can extend peripherally about the longitudinal axis between opposing first and second ends. The first end can be secured on the first end member such that a substantially fluid-tight seal is formed therebetween and the second end can be secured on the second end member such that a substantially fluid-tight seal is formed therebetween. The flexible spring member and the first and second end members can at least partially define a spring chamber. An internal conductor can be at least partially disposed within at least one of the gas spring chamber, the damper housing and the damper rod. A seal cap can be secured to the first end member such that a substantially fluid-tight connection is formed therebetween. The seal cap can include a seal cap body having a longitudinal axis and can extend radially outward from along the longitudinal axis. The seal cap body can include a first end surface portion that is disposed along a first side of the gas spring seal cap and a second end surface portion that is disposed along a second side of the gas spring seal cap. The second side of the gas spring seal cap is spaced longitudinally from the first side and the second end surface portion faces opposite the first end surface portion. An outer peripheral surface portion can be disposed between the first and second end surface portions. An electrical conductor can extend through the seal cap body. The electrical conductor can be disposed radially inward from the outer peripheral surface and can include a first terminal end conductively accessible from along the first end surface portion of the seal cap body. The electrical conductor can also include a second terminal end that is conductively accessible from along the second end surface portion of the seal cap body with the second terminal end conductively connected to the internal conductor. The electrical conductor can include a substantially impermeable portion having a substantially fluid-tight connection with the seal cap body. The substantially impermeable portion of the electrical conductor substantially inhibiting fluid communication across the seal cap body through the electrical conductor.

One example of a method of assembling a gas spring and damper assembly can include securing a flexible spring member to a first end member to at least partially define a spring chamber. The method can also include providing a damper including a damper housing and a damper rod operatively connected to one another such that the damper rod and damper housing can undergo relative reciprocal motion. The method can further include securing a gas spring end member to the damper rod of the damper such that the damper rod extends through the spring chamber. The method can also include extending an internal conductor through at least a portion of at least one of the gas spring chamber, the damper housing and the damper rod. The method can also include providing a gas spring seal cap according to any one of the foregoing paragraphs and conductively coupling the internal conductor to the second terminal end of at least one of the first and second electrical conductors of the gas spring seal cap. The method can further include securing the seal cap on the first end member such that a substantially fluid tight seal is formed between the seal cap and the first end member with the internal conductor conductively coupled with the first terminal end of the at least one of the first and second electrical conductors of the gas spring seal cap.

Turning now to the drawings, it is to be understood that the showings are for purposes of illustrating examples and 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 purposes of clarity and/or ease of understanding.

<FIG> illustrates one example of a suspension system <NUM> operatively disposed between a sprung mass, such as an associated vehicle body BDY, for example, and an unsprung mass, such as an associated wheel WHL or an associated suspension component 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.

For example, in the arrangement shown, suspension system <NUM> can include a plurality of gas spring and damper assemblies <NUM> 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 of gas spring and damper assemblies. For example, in the arrangement shown in <FIG>, suspension system <NUM> includes four gas spring and damper assemblies <NUM>, one of which is disposed toward each corner of the associated vehicle adjacent a corresponding wheel WHL. It will be appreciated, however, that any other suitable number of gas spring and damper assemblies could alternately be used in any other configuration and/or arrangement. As shown in <FIG>, gas spring and damper assemblies <NUM> are supported between suspension components SCP and body BDY of associated vehicle VHC. Gas spring and damper assemblies <NUM> can include a gas spring (or gas spring assembly) <NUM> and a damper (or damper assembly) <NUM> as well as a seal cap (not shown in <FIG>). It will be recognized that gas springs <NUM> are shown and described herein as being of a rolling lobe-type construction. It is to be understood, however, that gas spring assemblies of other types, kinds and/or constructions could alternately be used without departing from the subject matter of the invention, which is defined by the claims.

Suspension system <NUM> also includes a pressurized gas system <NUM> operatively associated with the gas spring and damper assemblies for selectively supplying pressurized gas (e.g., air) thereto and selectively transferring pressurized gas therefrom. As shown in the example in <FIG>, pressurized gas system <NUM> can include a pressurized gas source, such as a compressor <NUM>, for example, for generating pressurized air or other gases. A control device, such as a valve assembly <NUM>, for example, is shown as being in communication with compressor <NUM> and can be of any suitable configuration or arrangement. In the example shown, valve assembly <NUM> includes a valve block <NUM> with a plurality of valves <NUM> supported thereon. Valve assembly <NUM> can also, optionally, include a suitable exhaust, such as a muffler <NUM>, for example, for venting pressurized gas from the system. Optionally, pressurized gas system <NUM> can also include a reservoir <NUM> in fluid communication with the compressor and/or valve assembly <NUM> and suitable for storing pressurized gas.

Valve assembly <NUM> is in communication with gas springs <NUM> and/or dampers <NUM> of assemblies <NUM> through suitable gas transfer lines <NUM>. As such, pressurized gas can be selectively transferred into and/or out of the gas springs and/or the dampers through valve assembly <NUM> by selectively operating valves <NUM>, such as to alter or maintain vehicle height at one or more corners of the vehicle, for example.

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

One or more sensing devices, control devices and/or other electronic devices, which are collectively represented in <FIG> by boxes <NUM>, may be operatively associated with the gas spring and damper assemblies. As non-limiting examples, devices <NUM> can be capable of outputting or otherwise generating data, signals and/or other communications having a relation to - as non-limiting examples - one or more of: environmental, performance and/or operating conditions associated with suspension system <NUM> and/or any components and/or systems thereof; a height of the gas spring and damper assemblies; a distance between other components of the vehicle, a pressure or temperature having a relation to the gas spring and damper assembly and/or a wheel or tire or other component associated with the gas spring and damper assembly; and/or an acceleration, load or other input acting on the gas spring and damper assembly. As additional non-limiting examples, devices <NUM> can include control devices, such as electrically-actuatable valves, for example, that are operable to control fluid flow into, out of and/or within gas springs <NUM> and/or dampers <NUM>. Devices <NUM> can be communicatively coupled with one or more components and/or systems of control system <NUM>, such as ECU <NUM>, for example, and can send, receive or otherwise exchange data, signals and/or other communications therebetween. The sensing devices can be in communication with ECU <NUM> in any suitable manner, such as through conductors or leads <NUM>, 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.

Having described an example of a suspension system (e.g., suspension system <NUM>) that can include gas spring and damper assemblies, one example of such a gas spring and damper assembly will now be described in connection with <FIG>. As shown therein, a gas spring and damper assembly AS1, such as may be suitable for use as one or more of gas spring and damper assemblies <NUM> in <FIG>, for example, is shown as including a gas spring (or gas spring assembly) GS1, such as may correspond to one of gas springs <NUM> in <FIG>, for example, and a damper (or damper assembly) DP1 such as may correspond to one of dampers <NUM> in <FIG>, for example. Gas spring assembly GS1 and damper assembly DP1 can be disposed in an axially coextensive arrangement with one another, and can be operatively secured to one another in any suitable manner, such as is described hereinafter, for example. A longitudinal axis AX extends lengthwise along assembly AS1, as shown in <FIG>. Gas spring assembly GS1 can include a flexible spring member <NUM>, an end member (or end member assembly) <NUM> and an end member (or end member assembly) <NUM>, as described in greater detail hereinafter.

Damper assembly DP1 can include a damper housing <NUM> and a damper rod assembly <NUM> that is at least partially received in the damper housing. Damper housing <NUM> extends axially between housing ends <NUM> and <NUM>, and includes a housing wall <NUM> that at least partially defines a damping chamber <NUM>. Damper rod assembly <NUM> extends lengthwise between opposing ends <NUM> and <NUM> and includes an elongated damper rod <NUM> and a damper piston <NUM> disposed along end <NUM> of damper rod assembly <NUM>. Damper piston <NUM> is received within damping chamber <NUM> of damper housing <NUM> for reciprocal movement along the housing wall in a conventional manner. A quantity of damping fluid <NUM> can be disposed within damping chamber <NUM>, and damper piston <NUM> can be displaced through the damping fluid to dissipate kinetic energy acting on gas spring and damper assembly AS1. Though damper assembly DP1 is shown and described herein as having a conventional construction in which a hydraulic fluid is contained within at least a portion of damping chamber <NUM>, it will be recognized and appreciated that dampers of other types, kinds and/or constructions, such as pressurized gas or "air" dampers, for example, could be used without departing from the subject matter of the present invention as defined by the claims.

That is, it will be appreciated that a gas spring and damper assembly can, in some cases, include a damper of an otherwise conventional construction that utilizes hydraulic oil or other liquid as a working medium of the damper. In other cases, the damper can be of a type and kind that utilizes pressurized gas as a working medium. In such cases, such a gas damper can include one or more elongated gas damping passages through which pressurized gas can flow to generate pressurized gas damping to dissipate kinetic energy acting on the gas spring and damper assembly. It will be appreciated that such one or more elongated gas damping passages can be of any suitable size, shape, configuration and/or arrangement. Additionally, it will be appreciated that any number of one or more features and/or components can be used, either alone or in combination with one another, to form or otherwise establish such one or more elongated gas damping passages.

Housing wall <NUM> can include a side wall portion <NUM> that extends peripherally about longitudinal axis AX and can form an opening (not numbered) along housing end <NUM>. Housing wall <NUM> can also include a damper end wall <NUM> that can extend across the opening, and can include a passage (not numbered) through which elongated damper rod <NUM> can extend axially outward from damping chamber <NUM> in a direction opposite housing end <NUM>. Additionally, a damper end wall (not numbered) can be connected across end <NUM> of damper housing <NUM> such that a substantially fluid-tight connection is formed therebetween.

Elongated damper rod <NUM> can project outwardly from damper end wall <NUM> such that end <NUM> of the damper rod assembly is outwardly exposed from the damper housing and is externally accessible with respect to the damper housing. A connection feature <NUM>, such as a plurality of threads, for example, can be provided on or along the elongated rod for use in operatively connecting gas spring and damper assembly <NUM> to an associated vehicle structure, a component of gas spring assembly GS1 or another component of gas spring and damper assembly <NUM>. In some cases, a securement device <NUM>, such as a threaded fastener, for example, can be operatively engaged with connection feature <NUM> to secure elongated damper rod on or along end member assembly <NUM>.

It will be appreciated that gas spring and damper assembly AS1 can be operatively connected between associated sprung and unsprung masses of an associated vehicle (or other construction) in any suitable manner. For example, one end of the assembly can be operatively connected to an associated sprung mass with the other end of the assembly disposed toward and operatively connected to an associated unsprung mass. As shown in <FIG>, for example, end <NUM> of damper rod assembly <NUM> can be operatively engaged (either directly or indirectly) with a first or upper structural component USC, such as associated vehicle body BDY in <FIG>, for example, and can be secured thereon in any suitable manner. Additionally, or in the alternative, damper assembly DP1 can include a mounting bracket <NUM> disposed along end <NUM> of damper housing <NUM>, which can be secured on or along a second or lower structural component LSC (<FIG>), such as associated axle AXL in <FIG>, for example, and can be secured thereon in any suitable manner.

As discussed above, gas spring assembly GS1 can include flexible spring member <NUM> that can extend peripherally around axis AX and can be secured between opposing end members (or end member assemblies) <NUM> and <NUM> in a substantially fluid-tight manner such that a spring chamber <NUM> is at least partially defined therebetween. End member <NUM> can be secured on or along damper housing <NUM> in a suitable manner. End member <NUM> can include an end member wall <NUM> that can include any suitable number of one or more walls and/or wall portions. A support ring <NUM> can be secured on or along the exterior of damper housing <NUM>. A rotational support and sealing assembly <NUM> can be operatively disposed between end member <NUM> and support ring <NUM>. For example, assembly <NUM> can form a substantially fluid-tight connection between damper housing <NUM> and end member <NUM> that also permits rotational movement of the end member relative to the damper housing. In a preferred arrangement, end member <NUM> is supported on or along damper housing <NUM> such that forces and loads acting on one of upper and lower structural components USC and LSC can be transmitted or otherwise communicated to the other of upper and lower structural components USC and LSC at least partially through gas spring and damper assembly AS1.

It will be appreciated that flexible spring member <NUM> 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 <NUM> is shown in <FIG> and <FIG> as including a flexible wall <NUM> 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 unreinforced, 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.

Flexible wall <NUM> can extend in a generally longitudinal direction between opposing ends <NUM> and <NUM>. Additionally, flexible wall <NUM> can include an outer surface <NUM> and an inner surface <NUM>. The inner surface can at least partially define spring chamber <NUM> of gas spring assembly GS1. Flexible wall <NUM> can include an outer or cover ply (not identified) that at least partially forms outer surface <NUM>. Flexible wall <NUM> can also include an inner or liner ply (not identified) that at least partially forms inner surface <NUM>. In some cases, flexible wall <NUM> can further include one or more reinforcing plies (not shown) disposed between outer and inner surfaces <NUM> and <NUM>. 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.

Flexible spring member <NUM> can include any feature or combination of features suitable for forming a substantially fluid-tight connection with end member <NUM> and/or end member <NUM>. As one example, flexible spring member <NUM> can include open ends that are secured on or along the corresponding end members by way of one or more crimp rings <NUM> and <NUM>. Alternately, a mounting bead (not shown) can be disposed along either or both of the ends of the flexible wall. In some cases, the mounting bead, if provided, can, optionally, include a reinforcing element, such as an endless, annular bead wire, for example. In some cases, a restraining cylinder <NUM> and/or other components can be disposed radially outward along flexible wall <NUM>. In some cases, such components can be secured on or along the flexible wall in a suitable manner, such as by way or one or more backing rings <NUM>, for example.

As mentioned above, gas spring and damper assembly AS1 can be disposed between associated sprung and unsprung masses of an associated vehicle in any suitable manner. For example, one component can be operatively connected to the associated sprung mass with another component disposed toward and operatively connected to the associated unsprung mass. As illustrated in <FIG>, for example, end member assembly <NUM> can be operatively disposed along upper structural component USC, such as associated vehicle body BDY in <FIG>, for example, and can be secured thereon in any suitable manner.

Additionally, it will be appreciated that the 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 some cases, the end member can of a type or kind that is formed from one or more walls and/or wall portions. As a non-limiting example, end member (or end member assembly) <NUM> can be of a type commonly referred to as a reservoir housing and can include a plurality of walls and/or wall portions that at least partially define an end member chamber <NUM>. In the arrangement shown in <FIG>, end member assembly <NUM> is shown as including an end member housing (or housing section) <NUM> and an end member housing (or housing section) <NUM> that are secured together to at least partially define end member assembly <NUM>. It will be appreciated that housing section <NUM> and housing section <NUM> can together at least partially define end member chamber <NUM>. It will be appreciated that housing sections <NUM> and <NUM> can be secured together in any suitable manner, such as by way of one or more threaded fasteners and/or by one or more flowed-material joints. In a preferred arrangement, end member housing <NUM> can be at least partially formed from a first material, such as a metal material, for example, and end member housing <NUM> can be formed from a second material, such as a polymeric material, that is different than the first material. In such cases, housing sections <NUM> and <NUM> can, for example, be secured in abutting engagement with one another by way of a crimp ring <NUM> that extends peripherally about the housing sections and retains the housing sections in a substantially fixed axial position relative to one another.

It will be appreciated that gas spring and damper assembly AS1 is displaceable, during use in normal operation, between extended and compressed conditions. In some cases, one or more jounce bumpers can be included to inhibit contact between one or more features and/or components of assembly AS1. For example, a jounce bumper <NUM> can be included on or along elongated damper rod <NUM> within spring chamber <NUM> adjacent end member assembly <NUM> to substantially inhibit contact between a component of damper assembly DP1 and end member assembly <NUM> during a full jounce condition of assembly AS1. It will be appreciated, however, that other configurations and/or arrangements could alternately be used.

End member housing <NUM> can include any suitable number of walls and/or wall portions. For example, end member housing <NUM> is shown in <FIG> and <FIG> as including a housing wall <NUM> with an outer end wall portion <NUM> that is oriented transverse to longitudinal axis AX and extends radially outward to an outer side wall portion <NUM> that extends axially from along outer end wall portion <NUM> toward a distal edge <NUM>. In some cases, an annular groove <NUM> or other similar features can be disposed along outer side wall portion <NUM>, such as may be suitable for sealingly receiving a sealing element <NUM>. An outer peripheral wall portion <NUM> extends radially outward from along outer side wall portion <NUM> to an outer peripheral edge <NUM>. An inner side wall portion <NUM> extends axially from along outer end wall portion <NUM> toward a distal edge <NUM>. Additionally, a side wall portion <NUM> can, optionally, extend axially from along outer end wall portion <NUM> in a direction opposite inner side wall portion <NUM> to a distal edge <NUM> that faces opposite distal edge <NUM>. An inner end wall portion <NUM> can extend radially inward from along inner side wall portion <NUM> and/or side wall portion <NUM> toward an inner peripheral edge <NUM> that together with inner surface portions <NUM> and/or <NUM> of side wall portions <NUM> and/or <NUM>, respectively, can at least partially define a passage <NUM> through end member housing <NUM> that is dimensioned to receive and retain a seal cap 600A-D.

In some cases, an annular groove <NUM> and/or similar engagement feature can extend radially outward into side wall portion <NUM> and may be dimensioned to receive at least a portion of a retaining ring <NUM> or other similar component, for example. Additionally, an annular groove <NUM> can extend radially outward into side wall portion <NUM> in axially-spaced relation to annular groove <NUM>, such as may be suitable for sealingly receiving a seal component <NUM> that can be dimensioned to form a substantially fluid-tight seal on, along or otherwise with seal cap 600A-D, for example. Housing wall <NUM> can also include one or more features, such as a shoulder surface <NUM>, for example, dimensioned to axially support seal cap 600A-D on or along end member housing <NUM>. As one example, shoulder surface <NUM> could be spaced axially from annular groove <NUM> such that seal cap 600A-D can be captured between shoulder surface <NUM> and retaining ring <NUM>, for example. Additionally, outer peripheral wall portion <NUM> can include opposing surface portions <NUM> and <NUM>. Outer end wall portion <NUM> can include an inner surface portion <NUM> and/or inner side wall portion <NUM> can include an outer surface portion <NUM>. Inner surface portion <NUM> and/or outer surface portion <NUM> can at least partially define housing chamber <NUM>.

End member housing <NUM> can include any suitable number of walls and/or wall portions. For example, end member housing <NUM> is shown in <FIG> and <FIG> as including a housing wall <NUM> with an end wall portion <NUM> that is oriented transverse to longitudinal axis AX and extends radially outward toward an outer side wall portion <NUM>. An inner surface portion <NUM> is disposed along outer side wall portion <NUM> and at least partially defines housing chamber <NUM>. Outer side wall portion <NUM> extends axially from along end wall portion <NUM> to a distal end wall portion <NUM> that includes an outer peripheral edge <NUM> as well as opposing surface portions <NUM> and <NUM>. A crimp wall portion <NUM> is disposed radially inward of outer side wall potion <NUM> and extends from along end wall portion <NUM> in a direction away from outer side wall portion <NUM>. Crimp wall portion <NUM> can include one or more securement features <NUM> (e.g., annular grooves) disposed therealong and dimensioned to abuttingly engage and retain end <NUM> of flexible spring member <NUM>. Housing wall <NUM> also includes an inner end wall portion <NUM> that extends between and operatively interconnects crimp wall portion <NUM> with an inner side wall portion <NUM> that extends axially in a direction away from the inner end wall portion toward a distal end <NUM>. Inner side wall portion <NUM> can include a surface portion <NUM> facing radially inward and a surface portion <NUM> facing radially outward that can at least partially define housing chamber <NUM>. Inner side wall portion <NUM> can be dimensioned to receivingly engage inner side wall portion <NUM> such that the wall portions are axially coextensive with inner surface portion <NUM> and surface portion <NUM> disposed in facing relation to one another. In some cases, an annular groove <NUM> or other similar feature can be disposed along inner side wall portion <NUM>, such as may be suitable for sealingly receiving a sealing element <NUM>, for example. In some cases, one or more other walls and/or wall portions of housing wall <NUM> can include one or more passage formed therethrough, such as may be suitable for permitting fluid transfer and/or other access/communication to, from and/or otherwise between spring chamber <NUM> and end member chamber <NUM>. As a non-limiting example, inner end wall portion <NUM> can include one or more holes, openings or passages <NUM> formed or otherwise extending at least partially therethrough.

In an assembled condition, surface portion <NUM> of end member housing <NUM> and surface portion <NUM> of end member housing <NUM> are disposed in facing relation to one another. Crimp ring <NUM> can extend peripherally around outer peripheral wall portion <NUM> and distal end wall portion <NUM> to retain the end member housings in an assembled condition such that end member chamber <NUM> can, in some cases, be at least partially defined therebetween. Additionally, it will be recognized and appreciated that gas spring and damper assembly AS1 can include any suitable number of one or more other features, components, assemblies and/or systems. As a non-limiting example, a bushing BSG can be received within passage portion <NUM>, such as along inner surface portion <NUM> and operatively engage one or more components of damper assembly DP1. In some cases, bushing BSG could have one or more component portions that are electrically operable or otherwise conductively coupled to one or more other systems or components, such as zero or more electromagnetic coils EMC, for example. As another non-limiting example, damper assembly DP1 could be of a type and/or kind that is electrically variable, receives and/or generates electrical sensor signals and/or is otherwise conductively coupled to one or more other systems and/or components. Such non-limiting examples of performance variable components, sensors and/or other systems and/or devices are collectively represented in <FIG> by boxes PVC as being communicatively coupled by way of conductors or leads DPC. As a further non-limiting example, gas spring and damper assembly AS1 can include zero or more sensors, zero or more communication devices and/or zero or more control devices that are electrically powered and/or otherwise conductively coupled with one or more other systems and/or components. Non-limiting examples of sensors and/or communication devices can include height or distance sensors, acceleration sensors, temperature sensors, pressure sensors and/or communication sensors such as may be suitable for communicating with another remotely located system or device, such as tire pressure sensors through a wireless communication protocol. All of such non-limiting and merely exemplary sensors and communication devices are collectively represented in <FIG> by box SDS as being conductively coupled by way of conductors or leads SDC. Additionally, or in the alternative, gas spring and damper assembly AS1 can include zero or more control devices, such as may be operable to permit and/or inhibit fluid communication into, out of and/or between gas spring assembly GS1 and/or any components or volumes associated therewith. All of such control devices are collectively represented in <FIG> by box GDS as being conductively coupled by way of conductors or leads GDC. Any one or more of such systems and/or components can be conductively coupled with conductors or leads EXC that are external to gas spring and damper assembly AS1, such as may be communicatively coupled with an associated system or device (e.g., ECU <NUM> of control system <NUM>), such as by way of a suitable vehicle communication protocol. In some cases, conductors or leads DPC, SDC, GDC and/or EXC can include a connector CNN disposed therealong that is adapted to cooperatively engage seal cap 600A-D, such as is discussed hereinafter.

It will be appreciated that conductors or leads, DPC, SDC, and/or GDC can extend through gas spring and damper assembly AS1 and into engagement with seal cap 600A-D in any suitable manner. As a non-limiting example, conductors or leads DPC are shown in <FIG> as extending through a passage <NUM> disposed along at least a portion of elongated damper rod <NUM>. As another non-limiting example, zero or more of the conductors or leads can extend through spring chamber <NUM> and/or end member chamber <NUM>. In the exemplary arrangement shown in <FIG>, <FIG> and <FIG>, housing wall <NUM> can include one or more passages or ports <NUM> extending through end member housing <NUM>. Zero or more of conductors or leads DPC, SDC and/or GDC can extend through passages <NUM> and into area 542A of passage <NUM> for engagement with seal cap 600A-D.

Seal caps are operative to provide a substantially fluid-tight seal across an open end of a passage through which one or more electrical conductors are desired to extend. Seal caps include one or more conductive elements that are at least partially embedded in the seal cap such that electrical conductivity through the seal cap is available while also providing a substantially fluid-tight seal across the open end of the passage. In this manner, electrical signals can be communicated from a side of the seal cap exposed to a first gas pressure level (e.g., spring pressure) to the opposing side of the seal cap which may be exposed to a second gas pressure level (e.g., atmospheric pressure) that is different from the first gas pressure level. In this manner, systems and/or devices within or on one portion of the gas spring and damper assembly can be communicatively coupled with systems and/or devices outside of or on another portion of the gas spring and damper assembly.

It will be appreciated that seal cap constructions of a variety of types and kinds can be used, such as are shown as non-limiting examples in <FIG> and <FIG>. For example, seal caps 600A-D are shown in <FIG> and <FIG> as being secured along end member housing <NUM> of end member assembly <NUM>, such as, for example, by as being supported between shoulder surface <NUM> and retaining ring <NUM> thereby separating passage <NUM> into a first area 542A that is exposed to a first gas pressure level (e.g., spring pressure) and a second area 542B that is exposed to a second pressure level (e.g., atmospheric pressure). Seal caps 600A-D can also form a substantially fluid-tight seal across passage <NUM> in a suitable manner, such as by sealingly engaging sealing component <NUM>, for example.

In the exemplary arrangements shown, seal caps 600A-D include a seal cap body or wall <NUM> with a wall portion <NUM> that extends radially outward toward an outer peripheral surface portion or edge <NUM>. Seal cap wall <NUM> can also include a wall portion <NUM> disposed radially inward of wall portion <NUM>. In some cases, the wall portions can be disposed in an approximately common plane with one another. In other cases, however, wall portions <NUM> and <NUM> can be disposed in axially-spaced relation to one another with a wall portion <NUM> extending therebetween and operatively connecting wall portions <NUM> and <NUM>. It will be appreciated that wall portion <NUM> can be of any suitable shape or configuration, such as a having a an approximately linear or curvilinear cross-sectional profile or shape. In the arrangement shown in <FIG> and <FIG>, wall portion <NUM> is disposed at a non-zero angle relative to wall portions <NUM> and <NUM>, which are approximately planar. And, seal caps 600A-D are oriented relative to end member housing <NUM> such that the offset of wall portion <NUM> increases the size of area 542A in comparison with being oriented with wall portion <NUM> being disposed toward end member housing <NUM>. Seal cap wall <NUM> of seal caps 600AD also includes opposing surfaces <NUM> and <NUM> with surface <NUM> generally exposed to the first gas pressure level (e.g., spring pressure) and surface <NUM> exposed to the second gas pressure level (e.g., atmospheric pressure).

Seal caps in accordance include one or more conductive elements at least partially embedded therein such that a substantially fluid-tight seal is formed between the one or more conductive elements and the seal cap wall. In a preferred arrangement, at least a portion of the one or more conductive elements will include a substantially air-impermeable portion that will substantially inhibit the transfer of pressurized gas through the conductive elements. As a non-limiting example, the one or more conductive elements can include at least a section of solid, non-stranded wire that is embedded within the seal cap wall. In some cases, substantially all of the conductive element can be formed from solid, non-stranded wire. In this manner, exposed conductive ends of the one or more conductive elements can conductively communicate across the seal cap wall while substantially inhibiting pressurized gas flow across the seal cap wall.

In the arrangement shown in <FIG> and <FIG>, for example, a seal cap 600A includes electrical conductors <NUM> and <NUM> that are at least partially embedded within seal cap wall <NUM>, such that a substantially fluid-tight connection is formed therewith as is represented in <FIG> by dashed lines <NUM>. It will be appreciated that electrical conductors <NUM> and <NUM> can be of any suitable size, shape, and/or configuration and can be formed from any suitable electrically conductive material or combination of electrically conductive and non-electrically conductive materials. Additionally, in a preferred arrangement, seal cap wall <NUM> can be at least partially formed from a substantially nonelectrically conductive material. In which case, electrical conductors <NUM> and <NUM> can be directly embedded within the seal cap without permitting conductive cross-communication between the two or more electrical conductors. In the arrangement shown in <FIG> and <FIG>, electrical conductors <NUM> and <NUM> are approximately linear and are disposed in offset alignment with one another (e.g., substantially parallel) with conductor portions 616A and 618A exposed within area 542A for communicative coupling with connector CNN and one or more of conductors DPC, SDC and/or GDC while conductor portions 616B and 618B are exposed within area 542B for communicative coupling with connector CNN of conductor EXC.

Another exemplary construction of a seal cap 600B is shown in <FIG> and includes seal cap wall <NUM> that includes wall portions <NUM>, <NUM> and <NUM>, as described above. Seal cap 600B also includes electrical conductors <NUM> and <NUM>, which differ from the electrical conductors shown and described in connection with <FIG> and <FIG> in that at least a portion of the electrical conductors in <FIG> extend laterally (i.e., transverse to longitudinal axis AX) Additionally seal cap wall <NUM> in <FIG> includes an outer side wall portion <NUM> extending axially from along surface <NUM> and an outer side wall portion <NUM> extending axially from along surface <NUM>. In some cases, the outer side wall portions can include one or more retention features (e.g., barbs) and connectors CNN can include corresponding retention features to cooperatively engage the retention features on or along outer side wall portions <NUM> and/or <NUM>.

Yet another exemplary construction of a seal cap 600C is shown in <FIG> and includes seal cap wall <NUM> that includes wall portions <NUM>, <NUM> and <NUM>, as described above. Seal cap 600C also includes electrical conductors <NUM> and <NUM>, which differ from the electrical conductors shown and described in connection with <FIG>, <FIG> and <FIG> in that electrical conductors <NUM> and <NUM> are shown as being sections of an electrical fitting with separate conductive portions (i.e., conductors <NUM> and <NUM>). Additionally, a portion of the electrical connector fitting is exposed along both of surfaces <NUM> and <NUM> while retaining a substantially fluid-tight connection across the seal cap as indicated by dashed lines <NUM>.

A further exemplary construction of a seal cap 600D is shown in <FIG> and includes a seal cap wall <NUM> with a wall portion <NUM> that extends radially outward toward an outer peripheral edge <NUM>. Seal cap wall <NUM> can also include a wall portion <NUM> disposed radially inward of wall portion <NUM>. Seal cap 600D differs from seal caps 600A-C in that wall portions <NUM> and <NUM> are disposed in an approximately common plane with one another. Wall portion <NUM> extends axially outward beyond wall portion <NUM> toward wall portion end surfaces 608A and 608B. Electrical conductors <NUM> and <NUM> extend axially through wall portion <NUM> and include conductor portions 616A and 618A disposed along surface <NUM> that extend in a first lateral direction (e.g., in a direction transverse to axis AX) as well as conductor portions 616B and 618B disposed along surface <NUM> that extend in a second lateral direction (e.g., a direction transverse to axis AX) that is opposite the first lateral direction.

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.

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.

Claim 1:
A gas spring seal cap (600A;600B;600C;600D) dimensioned for securement to an associated end member (<NUM>;<NUM>;<NUM>), said gas spring seal cap (600A;600B;600C;600D) comprising:
a seal cap body (<NUM>) having a longitudinal axis (AX) and extending radially outward from along said longitudinal axis (AX), said seal cap body (<NUM>) at least partially formed from a substantially nonelectrically conductive material and including:
a first end surface portion (<NUM>) disposed along a first side of said gas spring seal cap (600A;600B;600C;600D);
a second end surface portion (<NUM>) disposed along a second side of said gas spring seal cap (600A;600B;600C;600D) that is spaced longitudinally from said first side and facing opposite said first end surface portion (<NUM>); and,
an outer peripheral surface portion (<NUM>) disposed between said first and second end surface portions (<NUM>,<NUM>); and,
a first electrical conductor (<NUM>) and a second electrical conductor (<NUM>) extending through said seal cap body (<NUM>), each of said first and second electrical conductors (<NUM>,<NUM>) formed substantially of electrically conductive material directly embedded within said seal cap body (<NUM>) without permitting conductive cross-communication between said first and second electrical conductors (<NUM>,<NUM>) through said substantially nonelectrically conductive material, each of said first and second electrical conductors (<NUM>,<NUM>) disposed radially inward from said outer peripheral surface portion (<NUM>) and including:
a first terminal end (616B,618B) conductively accessible from along said first end surface portion (<NUM>) of said seal cap body (<NUM>); and,
a second terminal end (616A,618A) conductively accessible from along said second end surface portion (<NUM>) of said seal cap body (<NUM>);
said first and second terminal ends (616B;618B,616A;618A) adapted for conductive coupling with an associated electrical connector (DPC;GDC;SDC); and,
each of said first and second electrical conductors (<NUM>,<NUM>) including a substantially air-impermeable portion having a substantially fluid-tight connection (<NUM>) with said seal cap body (<NUM>) with said substantially air-impermeable portion of each of said first and second electrical conductors (<NUM>,<NUM>) substantially inhibiting fluid communication across said seal cap body (<NUM>) through a respective one of said first and second electrical conductors (<NUM>,<NUM>).