End member assemblies as well as gas spring assemblies and methods of manufacture including same

A gas spring assembly comprising:

• a flexible spring member having a longitudinal axis and extending between a first end and a second end opposite said first end, said flexible spring member extending peripherally about said longitudinal axis such that a spring chamber is at least partially defined by said flexible spring member between said first and second ends;
• an end member extending across said first end of said flexible spring member and secured to said flexible spring member such that a substantially fluid-tight seal is formed therewith;
• and,
• an end member assembly including:
• a base plate including a base plate wall formed from a substantially rigid material and dimensioned for securement to an associated structural component;
• a mounting plate including a mounting plate wall formed from a substantially rigid material and dimensioned for securement to an end of the associated flexible spring member;
• and,
• a compliant support structure secured between said base plate and said mounting plate, said compliant support structure including a compliant element having a body at least partially formed from a compliant material and at least one reinforcing ply at least partially embedded within said body, said at least one reinforcing ply operative to restrict radially-outward expansion of said at least one compliant element under compression of said gas spring assembly.

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

• providing a flexible spring member having a longitudinal axis, said flexible spring member extending between a first end and a second end opposite said first end, and said flexible spring member extending peripherally about said longitudinal axis such that a spring chamber can be at least partially defined by said flexible spring member between said first and second ends;
• providing an end member and securing said end member across said first end of said flexible spring member such that a substantially fluid-tight seal is formed between said end member and said flexible spring member;
• and,
• providing an end member assembly including a base plate, a mounting plate and a compliant support structure, said base plate including a base plate wall formed from a substantially rigid material and dimensioned for securement to an associated structural component, said mounting plate including a mounting plate wall formed from a substantially rigid material and disposed in axially-spaced relation to said base plate with said compliant support structure secured between said base plate and said mounting plate, said compliant support structure including a compliant element having a body at least partially formed from a compliant material and at least one reinforcing ply at least partially embedded within said body, said at least one reinforcing ply operative to restrict radially-outward expansion of said at least one compliant element under compression of said gas spring assembly;
• securing said end member assembly across said second end of said flexible spring member such that a substantially fluid-tight seal is formed between said end member assembly and said flexible spring member.