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;
• securing said second end member across said second end of said flexible spring member such that a substantially fluid-tight seal is formed therebetween;
• 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 inner sleeve with said damper piston separating said piston chamber into first and second chamber portions;
• providing an end plate that includes an elongated damping passage having a spiral configuration and extending between a first passage end and a second passage end;
• positioning said end plate along said end wall portion of said end member wall of said second end member and connecting at least one of said first and second chamber portions in fluid communication with said spring chamber through 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;
• 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 wall portion including a first end surface portion facing toward said first end member and a second end surface portion facing away from said first end member, said end member wall at least partially defining an end member cavity disposed radially inward of said outer side wall portion;
• 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 inner sleeve, said damper piston separating said piston chamber into first and second chamber portions;
• and,
• an end plate including a first plate surface portion and a second plate surface portion, said end plate disposed adjacent said end wall portion of said end member wall of said second end member such that said first plate surface portion is oriented in facing relation to said second end surface portion, said end plate including an 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 said damping chamber;
• 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.