Patent ID: 12202311

DETAILED DESCRIPTION

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 such examples 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.1illustrates one example of a suspension system100operatively 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 system100can include a plurality of gas spring and damper assemblies102that 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 inFIG.1, suspension system100includes four gas spring and damper assemblies102, 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 inFIG.1, gas spring and damper assemblies102are supported between suspension components SCP and body BDY of associated vehicle VHC, and include a gas spring (or gas spring assembly)104and a damper (or damper assembly)106. It will be recognized that gas springs104are 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 present disclosure.

Suspension system100also includes a pressurized gas system108operatively associated with the gas spring and damper assemblies for selectively supplying pressurized gas (e.g., air) thereto and selectively transferring pressurized gas therefrom. In the exemplary arrangement shown inFIG.1, pressurized gas system108includes a pressurized gas source, such as a compressor110, for example, for generating pressurized air or other gases. A control device, such as a valve assembly112, for example, is shown as being in communication with compressor110and can be of any suitable configuration or arrangement. In the exemplary embodiment shown, valve assembly112includes a valve block114with a plurality of valves116supported thereon. Valve assembly112can also, optionally, include a suitable exhaust, such as a muffler118, for example, for venting pressurized gas from the system. Optionally, pressurized gas system108can also include a reservoir120in fluid communication with the compressor and/or valve assembly112and suitable for storing pressurized gas for an extended period of time (e.g., seconds, minutes, hours, weeks, days, months).

Valve assembly112is in communication with gas springs104and/or dampers106of assemblies102through suitable gas transfer lines122. As such, pressurized gas can be selectively transferred into and/or out of the gas springs and/or the dampers through valve assembly112by selectively operating valves116, such as to alter or maintain vehicle height at one or more corners of the vehicle, for example.

Suspension system100can also include a control system124that is capable of communication with any one or more systems and/or components of vehicle VHC and/or suspension system100, such as for selective operation and/or control thereof. Control system124can include a controller or electronic control unit (ECU)126communicatively coupled with compressor110and/or valve assembly112, such as through a conductor or lead128, for example, for selective operation and control thereof, which can include supplying and exhausting pressurized gas to and/or from gas spring and damper assemblies102. Controller126can be of any suitable type, kind and/or configuration.

Control system124can also, optionally, include one or more sensing devices130, such as, for example, may be operatively associated with the gas spring and damper assemblies 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 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. Sensing devices130can be in communication with ECU126, which can receive the data, signals and/or other communications therefrom. The sensing devices can be in communication with ECU126in any suitable manner, such as through conductors or leads132, 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 system100) that can include gas spring and damper assemblies in accordance with the subject matter of the present disclosure, an example of such a gas spring and damper assembly will now be described in connection withFIGS.2-9. 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 assemblies102inFIG.1, is shown as including a gas spring (or gas spring assembly) GS1, such as may correspond to one of gas springs104inFIG.1, for example, and a damper (or damper assembly) DP1such as may correspond to one of dampers106inFIG.1, for example. Gas spring assembly GS1and damper assembly DP1can 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 inFIGS.5and6.

Damper assembly DP1can include a damper housing200and a damper rod assembly202that is at least partially received in the damper housing. Damper housing200extends axially between housing ends204and206, and includes a housing wall208that at least partially defines a damping chamber210. Damper rod assembly202extends lengthwise between opposing ends212and214and includes an elongated damper rod216and a damper piston218disposed along end214of damper rod assembly202. Damper piston218is received within damping chamber210of damper housing200for reciprocal movement along the housing wall in a conventional manner. A quantity of damping fluid220can be disposed within damping chamber210, and damper piston218can be displaced through the damping fluid to dissipate kinetic energy acting on gas spring and damper assembly AS1. Though damper assembly DP1is shown and described herein as having a conventional construction in which a hydraulic fluid is contained within at least a portion of damping chamber210, 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 disclosure.

That is, it will be appreciated that a gas spring and damper assembly in accordance with the subject matter of the present disclosure 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 wall208can form an opening (not numbered) along housing end204. A damper end wall222can extend across the opening and can be secured on or along housing wall218such that a substantially fluid-tight connection is formed therebetween. Damper end wall222can include an opening (not numbered) and elongated damper rod216can extend axially outward from damping chamber210through the opening in a direction opposite housing end206. Additionally, a damper end wall (not numbered) can be connected across end206of damper housing200such that a substantially fluid-tight connection is formed therebetween. In some cases, an end cap224(which is sometimes referred to in the art as a striker cap) that includes an outer side surface portion226can be supported on or along end204of damper housing200. In other cases, an outside surface portion228of housing wall208can be exposed on or along end204of the damper housing.

Elongated damper rod216can project outwardly from damper end wall222such that end212of the damper rod assembly is outwardly exposed from the damper housing and is externally accessible with respect to the damper housing. A connection structure230, 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 assembly200, either directly or indirectly, to an associated vehicle structure, a component of gas spring assembly GS1or another component of gas spring and damper assembly AS1.

It will be appreciated that gas spring and damper assembly AS1can 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 inFIG.3, for example, end212of damper rod assembly202can be operatively engaged (either directly or indirectly) with a first or upper structural component USC, such as associated vehicle body BDY inFIG.1, for example, and can be secured thereon in any suitable manner. As one non-limiting example, gas spring and damper assembly AS1can include an end member assembly EM1that can be secured to upper structural component USC and to which one or more components of gas spring assembly GS1and/or one or more components of damper assembly DS1can be operatively connected. Additionally, or in the alternative, damper assembly DP1can include a mounting bracket232disposed along end206of damper housing200, which can be secured on or along a second or lower structural component LSC (FIG.3), such as associated suspension component SCP inFIG.1, for example, and can be secured thereon in any suitable manner.

Gas spring assembly GS1can include a flexible spring member300that can extend peripherally around axis AX and can be secured between opposing end members (or end member assemblies) in a substantially fluid-tight manner such that a spring chamber302is at least partially defined therebetween. As a non-limiting example, end member assembly EM1can include an end member (or end member body)400to which one end of flexible spring member300can be secured and an end member (or end member body)500to which end212of damper rod assembly202can be operatively connected. Additionally, or in the alternative, gas spring assembly GS1can include an end member assembly600that is supported on or along damper housing200. The end of flexible spring member300that is opposite end member400can be secured on or along end member assembly600in any suitable manner. Additionally, it will be appreciated that end member600can be operatively supported on or along damper housing200in a suitable manner. As a non-limiting example, damper housing200can include a support wall or support wall portion234that extends radially outward from along the damper housing toward an outer peripheral edge236with end member assembly600at least partially supported on or along support wall portion234.

It will be appreciated that flexible spring member300can 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 member300is shown inFIGS.2-8as including a flexible wall304that can be formed in any suitable manner and from any suitable material or combination of materials. For example, the flexible wall can include one or more fabric-reinforced, elastomeric plies or layers and/or one or more un-reinforced, elastomeric plies or layers. Typically, one or more fabric-reinforced, elastomeric plies and one or more un-reinforced, elastomeric plies will be used together and formed from a common elastomeric material, such as a synthetic rubber, a natural rubber or a thermoplastic elastomer. In other cases, however, a combination of two or more different materials, two or more compounds of similar materials, or two or more grades of the same material could be used.

Flexible wall304can extend in a generally longitudinal direction between opposing ends306and308. Additionally, flexible wall304can include an outer surface310and an inner surface312. The inner surface can at least partially define spring chamber302of gas spring assembly GS1. Flexible wall304can include an outer or cover ply (not identified) that at least partially forms outer surface310. Flexible wall304can also include an inner or liner ply (not identified) that at least partially forms inner surface312. In some cases, flexible wall304can further include one or more reinforcing plies (not shown) disposed between outer and inner surfaces310and312. 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 member300can include any feature or combination of features suitable for forming a substantially fluid-tight connection with end member400of end member assembly EM1and/or suitable for forming a substantially fluid-tight connection with end member assembly600. As one example, flexible spring member300can include open ends (not identified) that are secured on or along the corresponding end members by way of one or more crimp rings314and316. 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 cylinder318and/or other components can be disposed radially outward along flexible wall304. In some cases, such components can be secured on or along the flexible wall in a suitable manner, such as by way of one or more backing rings320, for example.

As mentioned above, gas spring and damper assembly AS1can 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 shown inFIGS.2-8, for example, end member500can include one or more securement devices502(e.g., threaded fasteners) operable to secure end member assembly EM1on or along upper structural component USC, such as associated vehicle body BDY inFIG.1, for example. Damper assembly DP1can be operatively connected to the upper structural component by way of end member assembly EM1, and can be operatively engaged with the end member assembly in any suitable manner.

For example, damper assembly DP1and/or end member assembly EM1can include a bushing assembly238that can be supported on or along end member500and to which damper rod assembly202is operatively connected. Additionally, or in the alternative, damper assembly DP1and/or end member assembly EM1can include a bushing assembly240that can be supported on or along end member500and to which damper rod assembly202is operatively connected. If included, bushing assembly238can include an inner metal242, an outer metal244and an elastomeric body246permanently attached (i.e., inseparable without damage, destruction or material alteration of at least one of the component parts) between the inner and outer metals. Additionally, or in the alternative, bushing assembly240, if included, can include an inner metal248, an outer metal250and an elastomeric body252permanently attached between the inner and outer metals. In such an arrangement, elongated damper rod218can extend through damper bushing238and/or damper bushing240, and can be secured therealong in a suitable manner, such as by way of a securement device254(e.g., a threaded nut) cooperatively engaging connection structure230of elongated damper rod216, for example.

In some cases, inner metal242can take the shape of an annular plate or disk that projects radially outward from an inner peripheral edge256toward an outer peripheral edge258with at least a portion of inner metal242embedded within elastomeric body246. In an assembled condition of the exemplary arrangement shown inFIGS.5and6, inner metal248can be positioned on or toward a step or shoulder surface portion260formed on or along elongated damper rod216toward end212thereof. Inner metal242can be positioned on, along or otherwise adjacent an end262of inner metal248with a spacer264(which is optional depending on the geometry of inner metal242) disposed on, along or otherwise adjacent inner metal242opposite inner metal248. A washer266can, optionally, be disposed on or along spacer264, if included, with securement device254both inner metals (through the spacer and/or washer, if included) toward shoulder surface portion260to at least partially secure elongated damper rod216on or along end member assembly EM1through bushing assembly238and/or bushing assembly240. One or more sealing devices268can be operatively disposed between elongated damper rod216and inner metal242and/or inner metal248such that a substantially fluid-tight seal is formed therebetween.

It will be appreciated that gas spring and damper assembly AS1is 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, damper assembly DP1can include a jounce bumper270positioned on or along elongated damper rod216within spring chamber302. It will be appreciated that the jounce bumper, if provided, can be supported in any suitable manner. As a non-limiting example, jounce bumper260can be supported on end member assembly500to substantially inhibit contact between a component of damper assembly DP1and end member assembly500during a full jounce condition of assembly AS1. It will be appreciated, however, that other configurations and/or arrangements could alternately be used.

End member assembly600is of a type and kind commonly referred to as a roll-off piston or piston assembly. It will be appreciated that end member assembly600can include any suitable number of one or more components and/or elements. For example, in the arrangement shown and described herein, end member assembly600includes an end member core602that is disposed along and supported on damper housing200. An end member shell (or shell section)604is supported on the end member core and can include an outer surface606along which a rolling lobe322of flexible spring member300can be displaced as gas spring and damper assembly AS1is displaced between compressed and extended conditions. It will be appreciated that end member core602can be configured to receive and support one or more end member shells and/or shell sections, such as may have any one of a wide variety of different sizes, shapes and/or configurations (e.g., outer profiles with different combinations of contours and/or shapes).

Additionally, it will be appreciated that end member assembly600and the one or more components and/or elements thereof can be formed from any suitable material or combination of materials, and can include any suitable number or combination of one or more walls and/or wall portions. For example, end member core602and/or end member shell sections604can be formed from a suitable polymeric material or combination of polymeric materials, such as a fiber-reinforced polypropylene, a fiber-reinforced polyamide, or an unreinforced (i.e., relatively high-strength) thermoplastic (e.g., polyester, polyethylene, polyamide, polyether or any combination thereof), for example.

End member core602is shown as extending peripherally about axis AX and longitudinally between opposing ends608and610. End member core602can include a first or upper mounting section612toward end608on or along which end308of flexible spring member300can be operatively connected in a suitable manner. For example, retaining ring316can be crimped radially-inward or otherwise deformed to form a substantially fluid-tight connection between end308of flexible spring member300and mounting section612of end member core602. In this manner, spring chamber302can be at least partially defined by flexible spring member300between end member400and end member assembly600, such as has been described above.

End member core602can be supported on or along damper housing200in any suitable manner. As one non-limiting example, an end surface portion614of end member core602along end610thereof can be disposed on or along support wall portion234of damper housing200to support the end member core on the damper housing in at least one axial direction. A sealing device616can be sealingly disposed between end member core602and damper housing200such that a substantially fluid-tight seal is formed therebetween. It will be appreciated, however, that other configurations and/or arrangements could alternately be used.

As discussed above, end member assembly EM1can be configured to interconnect flexible spring member300of gas spring assembly GS1and damper rod assembly202of damper assembly DP1as well as operatively connect the gas spring assembly and the damper assembly to an associated structural component, such as upper structural component USC, for example. End member (or end member body)400and end member (or end member body)500can be permanently interconnected in a substantially-fixed coextensive arrangement through the use of one or more attachment studs secured or otherwise provided on or along either or both of the end members. The one or more attachment studs extend axially through one or more attachment passages in the other one or both of the end members. A distal end of the attachment studs is permanently deformed into attachment heads that have a larger cross-sectional dimension than that of the attachment passages. The permanently (i.e., unalterable without damage, destruction or material alteration of at least one of the component parts) secures end members400and500together in a substantially-fixed axial position relative to one another.

In the arrangement shown and described herein, end member400includes the one or more attachment studs and end member500includes the one or more attachment passages. It will be appreciated, however, that an alternate construction in which end member400include the one or more attachment passages and end member500include the one or more studs is intended to find support in the subject disclosure as if such embodiments were fully shown and described herein. Additionally, or in the alternative, an alternate construction in which end member400and end member500each include one or more attachment studs and one or more attachment openings that are cooperative with one another is also intended to find full support in the subject disclosure as if such embodiments were fully shown and described herein.

End member400is shown and described herein as including an end member wall402that extends peripherally about longitudinal axis AX. End member wall402includes a side wall portion404with an inner surface portion406facing radially inward. Side wall portion404can include an outer surface portion408that is dimensioned to receive end306of flexible spring member for securement therealong in a suitable manner, such as by way of crimp ring314, for example. In some cases, end member wall402can include a side wall portion410that is disposed radially inward of side wall portion404such that an annular groove or channel412can be disposed therebetween. End member wall402at least partially defines an end member passage414that extends through end member400and is dimensioned to receive at least a portion of end member500. As such, side wall portion404and/or side wall portion410, if included, can at least partially define an inner surface portion416of end member wall402on or along which a corresponding outer surface portion of end member500can be positioned, such as is described hereinafter.

In some cases, a backing ring418can be disposed radially inward of side wall portion404to provide additional strength and/or rigidity to end member400, such as under a crimp load or force applied by crimp ring314, for example. A flange wall portion420is disposed transverse to longitudinal axis AX, and can extends radially outward beyond side wall portion404to an outer peripheral edge422. In some cases, flange wall portion420can also extend radially inward and operatively connect side wall portion404and side wall portion410, if included, such as may at least partially define a closed end of channel412, for example. Flange wall portion420of end member wall402includes a flange surface portion424from which at least side wall portion404extends toward a distal edge426. Flange wall portion420also includes a flange surface portion428facing opposite flange surface portion424.

With reference to the discussion set forth above regarding the inclusion herein of alternate constructions and as one example of an end member assembly in accordance with the subject matter of the present disclosure, end member400can include one or more attachment studs430operatively connected to end member wall402. In a preferred construction, a plurality of attachment studs430are included that are disposed in peripherally-spaced relation to one another around longitudinal axis AX. Attachment studs430can extend from along flange wall portion420axially away from flange surface portion428toward a distal end432. In some cases, attachment studs430can be integrally attached to end member wall402, such as on or along flange wall portion420thereof, for example. In a preferred arrangement, however, attachment studs430can be unitarily formed with end member wall402, such as on or along flange wall portion420, for example. In some cases, attachment studs430can include one or more holes434extending into the attachment studs from along distal end432thereof, such as may aid in formation of attachment heads during assembly, for example. Attachment studs430are shown inFIG.9prior to assembly as having an overall length extending from at least approximately flange surface portion428to at least approximately distal end432, as is represented by reference dimension LG1. After assembly, as discussed below, attachment studs430are permanently deformed and have an overall length extending from at least approximately flange surface portion428to a distal extent of stud heads (or attachment heads)430′, as is represented by reference dimension LG2. Additionally, attachment studs430are also shown prior to assembly as having a cross-sectional dimension, which is represented inFIG.9by reference dimension CD1and after being permanently deformed during assembly with stud heads430′ integrally formed from attachment studs430and having a cross sectional dimension represented by reference dimension CD2inFIG.7.

End member500is shown and described herein as including an end member wall504that extends peripherally about longitudinal axis AX. End member wall504includes a side wall portion506that extends axially from an end surface portion508toward an end surface portion510facing opposite end surface portion508. Side wall portion506can include an inner side surface portion512as well as an outer side surface portion514. End member wall504can also include a side wall portion516that is disposed radially inward of side wall portion506such that an annular groove or channel518can be disposed therebetween. Side wall portion516can include an inner side surface portion520facing radially inward.

End member wall504also includes a flange wall portion522that extends outwardly from along side wall portion506to an outer peripheral edge524. An end wall portion526extends radially inward from along side wall portion506. End wall portion526can operatively connect side wall portions506and516, and together therewith can at least partially define a recess528within which bushing assembly238and/or240are at least partially received and a recess530within which at least a portion of jounce bumper270can be received. End wall portion526can extend radially inward toward an inner peripheral edge532that at least partially defines an opening or passage534through end member500. Additionally, a seal536can be disposed between end members400and500, and it will be appreciated that any suitable configuration and/or arrangement can be used to receive and retain seal536in sealing engagement between the end members such that a substantially fluid-tight seal is maintained therebetween. As a non-limiting example, an annular groove538can be formed on or along outer side surface portion514of side wall portion506that is dimensioned to at least partially receive seal536. It will be appreciated, however, that other configurations and/or arrangements could alternately be used.

As discussed above, bushing assemblies238and/or240can be at least partially disposed within recess528of end member500and can be operatively secured thereto in any suitable manner. As a non-limiting example, bushing assembly240can, if included, be disposed within recess528with outer metal250and/or elastomeric body252disposed on or along end wall portion526such that the outer surface of outer metal250is disposed in facing relation to inner side surface portion520of side wall portion516. Additionally, or in the alternative, bushing assembly238can be disposed within recess528with outer metal244disposed in facing relation to inner side surface portion512of side wall portion506. In such cases, one or more sealing devices540can be operatively disposed between at least one of outer metals244and/or250and at least one of side wall portions506and/or516such that a substantially fluid-tight seal is formed therebetween. Optionally, an annular washer or disk542can be supported on an end surface portion (not numbered) of side wall portion516and/or outer metal250. If included, outer metal244can be supported on or along annular disk542. Additionally, or in the alternative, an annular washer or disk544can be disposed within recess528on or along outer metal244and/or elastomeric body246of bushing assembly238. Outer metal244and outer metal250, if included, can be secured within recess528in any suitable manner, such as by way of a retaining ring546operatively engaging a corresponding groove (not numbered) disposed along inner side surface portion512, for example.

Flange wall portion522of end member wall504includes a flange surface portion548facing in an axial direction toward end surface portion508and a flange surface portion550facing opposite side surface portion548. As such, flange wall portion522has a thickness or height between flange surface portions548and550, as is represented inFIG.7by reference dimension THK. Additionally, with repeated reference to the discussion set forth above regarding the inclusion herein of alternate constructions and as one example of an end member assembly in accordance with the subject matter of the present disclosure, end member500can include one or more attachment passages552extending through flange wall portion522. In a preferred arrangement, a plurality of attachment passages552can be used. In such cases, the plurality of attachment passages can be disposed in peripherally-spaced relation to one another around longitudinal axis AX. Attachment passages552have a cross-sectional dimension, which is represented inFIG.9by reference dimension CD3. As such, thickness THK of flange wall portion522together with overall length LG1of attachment studs430before assembly and overall length LG2of the attachment studs with stud heads430′ after assembly are represented by the relationship:
LG1≥LG2>THK
Additionally, cross-sectional dimension CD3of attachment passages552together with cross-sectional dimension CD1of attachment studs430and cross-sectional dimension CD2of stud heads430′ are represented by the relationship:
CD2>CD3>CD1

As discussed above, end member500can include a plurality of securement devices502(e.g., threaded fasteners) operatively connected to end member wall504, such as on or along flange wall portion522, for example. In the arrangement shown and described herein, flange wall portion522includes a plurality of holes554extending therethrough with one of securement devices502disposed within a corresponding one of holes554. In some cases, securement devices502can take the form of threaded fasteners that include a fastener head556that is disposed on or along flange surface portion550such that the securement devices extend through holes554with a remainder of the threaded fastener projecting axially outward beyond flange surface portion548. In some cases, flange wall portion544can include one or more recesses556formed therein from along flange surface portion550that are dimensioned to receive at least a portion of fastener head558.

In some cases, end member400can be at least partially formed from a first materials, such as a metal material, for example, and end member500can be formed from a second material, such as a polymeric material or combination of polymeric materials, that is different than the first material. As non-limiting examples, the first material could be steel, aluminum or zinc, whereas the second material could be a fiber-reinforced polypropylene, a fiber-reinforced polyamide, or an unreinforced (i.e., relatively high-strength) thermoplastic (e.g., polyester, polyethylene, polyamide, polyether or any combination thereof), for example.

In an assembled condition, end member500is at least partially received within passage414of end member400such that flange surface portion428and flange surface portion550are disposed in facing relation to one another. Additionally, in such an arrangement, each one of attachment studs430is aligned with and extends into and through a corresponding one of attachment passages552. In some cases, flange surface portions428and550can be disposed in abutting engagement with one another, such as is shown inFIGS.5-8, for example. Securement devices502are disposed in peripherally spaced relation to one another, and can include one or more of securement devices502disposed between adjacent ones of attachment studs430and/or attachment passages552. Once positioned coextensively with one another, end members400and500can be permanently secured together by permanently deforming a distal end of attachment studs430into attachment heads430′ that are unitarily formed from attachment studs430. Stud heads430′ are disposed in abutting engagement with flange surface portion426and have a larger cross-sectional dimension than that of the attachment passages, which permanently secures (i.e., inseparable without damage, destruction or material alteration of at least one of the component parts) end members400and500in a substantially-fixed axial position relative to one another.

One example of a method of assembling an end member assembly in accordance with the subject matter of the present disclosure includes providing a first end member such as one of end members400and500, for example. The method also includes providing a second end member such as the other one of end members400and500. The method can further include at least approximately rotationally aligning one or more of attachment studs430with corresponding ones of attachment passages552about the longitudinal axis. The method can also include positioning end members400and500axially coextensively such that one or more of attachment studs430extend into and through corresponding ones of attachment passages552. The method can further include permanently deforming distal end432of attachment studs430into attachment heads430′ that are unitarily formed from attachment studs430. Attachment heads430′ have a larger cross-sectional dimension than that of the attachment passages, which secures end members400and500in a substantially-fixed axial position relative to one another. As non-limiting examples, suitable techniques for permanently deforming attachment studs430to include unitarily-formed attachment heads430′ are sometimes referred to as thermoplastic staking or heat staking, as is represented inFIG.8by device TPS.

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.

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.

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.

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.