Damper rod bushings as well as gas spring and damper assemblies and methods including same

A gas spring and damper assembly comprising:

• a gas spring having a longitudinal axis and including:
• a first end member;
• a second end member spaced axially from said first end member;
• and,
• a flexible spring member extending peripherally about said longitudinal axis between opposing first and second ends, said first end secured on said first end member such that a substantially fluid-tight seal is formed therebetween and said second end secured on said second end member such that a substantially fluid-tight seal is formed therebetween with a spring chamber at least partially defined by said flexible spring member and said first and second end members;
• a damper extending longitudinally between and operatively connecting said first and second end members such that at least a portion of said damper extends through said spring chamber, said damper including:
• a damper housing operatively connected to said first end member and including a housing wall that at least partially defines a damping chamber;
• and,
• a damper rod assembly including a damper rod and a damper piston, said damper rod extending axially between a first end and a second end, said damper piston operatively secured to said second end of said damper rod;
• said damper rod assembly operatively engaged with said damper housing such that said damper piston is disposed within said damping chamber with at least said first end of said damper rod projecting outwardly from said damper housing and such that said damper rod assembly and damper housing can undergo reciprocal motion relative to one another;
• and,
• a damper rod bushing operatively connecting said second end member of said gas spring and said first end of said damper rod assembly of said damper with at least a portion of said damper rod bushing disposed in fluid communication with said spring chamber such that pre-load forces due to gas pressure within said spring chamber act on said damper rod bushing, said damper rod bushing extending axially between a first end and a second end, said damper rod bushing including:
• an outer support element including an inner surface;
• an inner support element extending between opposing first and second end surfaces and including an outer surface, an inner surface at least partially defining a passage through said inner support element that is dimensioned to receivingly engage said first end of said damper rod, and a flange wall portion projecting radially outward beyond said outer surface to an outer peripheral edge, said flange wall portion including a first side surface disposed toward said first end surface and a second side surface disposed toward said second end surface, said flange wall portion having a flange cross-sectional dimension (DF) across said outer peripheral edge, and said flange wall portion disposed in spaced relation to said opposing first and second end surfaces such that at least said second side surface is axially offset from said second end surface by a flange offset dimension (OFF);
• and,
• an elastomeric connector element operatively connected between said inner support element and said inner surface of said outer support element such that a substantially fluid-tight seal is formed therebetween, said elastomeric connector element being permanently attached along an annular joint extending axially in cross-sectional profile between a first attachment point disposed toward said first end of said damper rod bushing and a second attachment point disposed toward said second end of said damper rod bushing, said elastomeric connector element including:
• a first outer edge disposed along said outer support element toward said first end of said elastomeric bushing element, said first outer edge including a cross-sectional profile with a radius of curvature (R1) and defining an outermost axial extent of said first outer edge, said radius of curvature having a centerpoint spaced inward from said inner surface of said outer support element by a radius offset dimension (D1), said outermost axial extent of said first outer edge being axially offset from said first attachment point by an first unsecured edge dimension (D2);
• a second outer edge disposed along said outer support element toward said second end of said elastomeric bushing element, said second outer edge including an outermost axial extent axially offset from said second attachment point by a second unsecured edge dimension (D3);
• and,
• a base surface extending radially inward from along said second outer edge in abutting engagement along said first end member such that said base surface has a cross-sectional profile with a base surface engagement dimension (D4).