Gas spring and gas damper assemblies as well as suspension systems and methods of assembly

A method of manufacturing a gas spring and gas damper assembly, said method comprising:

• providing a flexible spring member having a longitudinal axis and including a flexible wall extending longitudinally between first and second ends and peripherally about said axis to at least partially define a spring chamber;
• providing a first end member and securing said first end member across said first end of said flexible spring member such that a substantially fluid-tight seal is formed therebetween;
• providing a second end member including an end member wall that includes an outer side wall portion that extends longitudinally along said second end member and an end wall portion oriented transverse to said longitudinal axis with said end member wall at least partially defining an end member cavity disposed radially inward of said outer side wall portion, said end wall portion including a first surface, a second surface facing opposite said first surface and an elongated damping passage having an open side along said second surface of said end wall portion, said elongated damping passage extending between a first passage end and a second passage end and having a spiral configuration disposed in a plane oriented transverse to said longitudinal axis;
• securing said second end member across said second end of said flexible spring member such that a substantially fluid-tight seal is formed therebetween and such that said first passage end of said elongated damping passage is disposed in fluid communication with said spring chamber and said second passage end is disposed in fluid communication with said end member cavity;
• providing an end plate including a port extending therethrough, and positioning said end plate within said end member cavity across said open side of said elongated damping passage such that said port is disposed in fluid communication with one of said first and second passage ends of said elongated damping passage whereby pressurized gas can transfer between said elongated damping passage and said end member cavity through said port in said end plate;
• providing a housing sleeve extending longitudinally between opposing sleeve ends, said housing sleeve including a sleeve wall with an inner surface and an outer surface;
• positioning said housing sleeve at least partially within said end member cavity such that said inner surface of said sleeve wall at least partially defines a damping chamber;
• providing a damper piston assembly including a damper piston and an elongated damper rod operatively connected to said damper piston, said damper piston including an outer side wall;
• positioning said damper piston within said damping chamber such that said outer side wall is disposed adjacent said inner surface of said sleeve wall with said damper piston separating said piston chamber into first and second chamber portions;
• connecting at least one of said first and second chamber portions in fluid communication with said spring chamber through said port of said end plate and said elongated damping passage;
• and,
• connecting said damper rod to said first end member such that upon extension and compression of said gas spring and gas damper assembly, said damper piston is reciprocally displaced within said damping chamber to generate pressurized gas damping with additional pressurized gas damping being generated from pressurized gas transfer between said spring chamber and said damping chamber through said elongated damping passage.

A gas spring and gas damper assembly comprising:

• a flexible spring member having a longitudinal axis and including a flexible wall extending longitudinally between first and second ends and peripherally about said axis to at least partially define a spring chamber;
• a first end member operatively secured to said first end of said flexible spring member such that a substantially fluid-tight seal is formed therebetween;
• and,
• a second end member disposed in spaced relation to said first end member and operatively secured to said second end of said flexible spring member such that a substantially fluid-tight seal is formed therebetween, said second end member including an end member wall that includes an outer side wall portion that extends longitudinally along said second end member and an end wall portion oriented transverse to said longitudinal axis, said end member wall at least partially defining an end member cavity disposed radially inward of said outer side wall portion with said end wall portion at least partially defining a closed end of said end member cavity, said end wall portion including a first surface facing said spring chamber and a second surface facing said end member cavity;
• a housing sleeve extending longitudinally between opposing sleeve ends, said housing sleeve including a sleeve wall with an inner surface and an outer surface, said housing sleeve at least partially received within said end member cavity with said inner surface of said sleeve wall at least partially defining a damping chamber;
• a damper rod assembly including a damper piston and an elongated damper rod operatively connected to said damper piston, said damper piston positioned within said damping chamber and including an outer side wall disposed adjacent said inner surface of said sleeve wall, said damper piston separating said piston chamber into first and second chamber portions;
• an elongated damping passage disposed along said end wall portion of said second end member wall, said elongated damping passage having a spiral configuration extending between a first passage end and a second passage end with said first passage end disposed in fluid communication with said spring chamber and said second passage end disposed in fluid communication with one of said first and second chamber portions;
• and,
• an end plate disposed within said end member cavity and extending across said open side of said elongated damping passage, said end plate including a port in fluid communication with said second passage end of said elongated damping passage such that pressurized gas is transferrable between said spring chamber and said damping chamber through said elongated damping passage by way of said port in said end plate;
• said damper rod operatively connected to said first end member such that upon extension and compression of said gas spring and gas damper assembly, said damper piston is reciprocally displaced within said damping chamber and pressurized gas damping is generated from at least pressurized gas transfer through said elongated damping passage between said spring chamber and said damping chamber.