BACKGROUND

[0001] The subject matter of the present disclosure broadly relates to the art of gas spring devices and, more particularly, to end members configured to generate a radially- unsupported rolling lobe during use with an associated flexible spring member. Gas spring assemblies can include such an end member as well as a flexible spring member. Suspension systems can include one or more of such gas spring assemblies.

[0002] The subject matter of the present disclosure may find particular application and use in conjunction with components for wheeled vehicles, and will be shown and described herein with reference thereto. However, it is to be appreciated that the subject matter of the present disclosure is also amenable to use in other applications and environments, and that the specific uses shown and described herein are merely exemplary. For example, the subject matter of the present disclosure could be used in connection with gas spring assemblies of non-wheeled vehicles, support structures, height adjusting systems and actuators associated with industrial machinery, components thereof and/or other such equipment. Accordingly, the subject matter of the present disclosure is not intended to be limited to use in association with gas spring suspension systems of wheeled vehicles.

[0003] Wheeled motor vehicles of most types and kinds include a sprung mass, such as a body or chassis, for example, and an unsprung mass, such as two or more axles or other wheel-engaging members, for example, with a suspension system disposed therebetween. Typically, a suspension system will include a plurality of spring devices as well as a plurality of damping devices that together permit the sprung and unsprung masses of the vehicle to move in a somewhat controlled manner relative to one another. Movement of the sprung and unsprung masses toward one another is normally referred to in the art as jounce motion while movement of the sprung and unsprung masses away from one another is commonly referred to in the art as rebound motion.

[0004] In some cases, the spring devices of vehicle suspension systems will include springs that utilize pressurized gas as the working medium of the devices. Such so- called gas suspension systems, which are commonly used in various vehicle applications vehicles, are known to provide the capability of adjusting the height and/or alignment (e.g., leveling) of a sprung mass (e.g., a body or chassis of a vehicle) relative to an unsprung mass thereof (e.g., a wheel-engaging member or axle housing of the vehicle). As such, known gas suspension systems commonly transfer pressurized gas into and out of gas spring assemblies that are operatively connected between the sprung and unsprung masses. In this manner, the gas suspension system can alter or otherwise adjust the height, alignment and/or other control the movement of the sprung mass relative to the unsprung mass.

[0005] In some cases, multiple gas springs of a gas suspension system may be fluidically interconnected with one another. Under certain conditions of use of conventional gas springs, pressurized gas may temporarily flow from one or more gas springs to one or more other gas springs. In such cases, the one or more conventional gas springs from which pressurized gas has been transferred may temporarily experience an under-inflation condition that can, in some cases, permit the rolling lobe of the flexible spring member to become disassociated from the outer surface of a conventional rolling lobe-style end member of the gas spring. Under such conditions, the flexible spring member slide along or otherwise undergo undesirable displacement with respect to the outer surface of the conventional end member.

[0006] Additionally, gas spring assemblies of various types, kinds and constructions are well known and commonly used. In some cases, it may be possible to reduce the spring rate of gas springs, thereby improving ride comfort, by increasing the volume of pressurized gas operatively associated with the gas spring. In other cases, however, packaging restrictions associated with the surrounding vehicle components or other structures will limit the space available for increasing the dimensions of the gas spring.

[0007] In view of the foregoing and notwithstanding the overall success of known constructions, it is believed that certain disadvantages of conventional constructions may still exist and that a need exists to meet the aforementioned competing goals while still retaining comparable or improved performance and other desired features. Accordingly, it is believed desirable to develop gas spring devices that overcome the foregoing and/or other problems and/or disadvantages of known designs, and/or otherwise advance the art of gas spring devices. BRIEF SUMMARY

[0008] One example of an end member in accordance with the subject matter of the present disclosure that is dimensioned for securement to an associated flexible spring member, such as for forming an associated gas spring assembly, can include an end member body having a longitudinal axis. The end member body can extend longitudinally between opposing first and second ends. The end member body can include an end member wall with a first outer side wall portion that extends in a generally longitudinal direction. The first outer side wall portion can include a first outer surface that at least partially defines an outermost periphery of the end member. A second outer side wall portion can extend in a generally longitudinal direction and is disposed radially inward from the first outer side wall portion. The second outer side wall portion can include a second outer surface. A first end wall portion can be disposed transverse to the longitudinal axis. The first end wall portion can extend between and operatively connect the first outer side wall portion and the second outer side wall portion. A second end wall portion can be disposed in longitudinally spaced relation to the first end wall portion. The second end wall portion can extend radially inward from the second outer side wall portion. A mounting wall portion can extend from along the first end wall portion in a generally longitudinal direction opposite the second outer side wall portion. The mounting wall portion can be dimensioned to receivingly engage an end of the associated flexible spring member.

[0009] One example of a gas spring assembly in accordance with the subject matter of the present disclosure can include a flexible spring member having a longitudinal axis. The flexible spring member can extend peripherally about the longitudinal axis between a first end and a second end opposite the first end. The flexible spring member can at least partially define a spring chamber. The first end member can be secured across the first end of the flexible spring member such that a substantially fluid-tight seal is formed therebetween. A second end member can be secured across the second end of the flexible spring member such that a substantially fluid-tight seal is formed therebetween. The second end member can include an end member wall with a first outer side wall portion that extends in a generally longitudinal direction . The first outer side wall portion can include a first outer surface that at least partially defines an outermost periphery of the second end member. A second outer side wall portion can extend in a generally longitudinal direction and can be disposed radially inward from the first outer side wall portion. The second outer side wall portion can include a second outer surface. A first end wall portion can be disposed transverse to the longitudinal axis. The first end wall portion can extend between and operatively connect the first outer side wall portion and the second outer side wall portion. A second end wall portion can be disposed in longitudinally spaced relation to the first end wall portion. The second end wall portion can extend radially inward from the second outer side wall portion. A mounting wall portion can extend from along the first end wall portion in a generally longitudinal direction opposite the second outer side wall portion. The mounting wall portion can be dimensioned to receivingly engage the second end of the flexible spring member. The flexible spring member can extend in abutting engagement from the mounting wall portion along the first end wall portion and the first outer side wall portion such that at a pre-determined design height of the gas spring assembly, a rolling lobe is formed along the flexible spring member. At the design height of the gas spring assembly, the rolling lobe can be disposed in axially spaced relation to the first and second end wall portions. And, at the design height of the gas spring assembly, the rolling lobe can be unsupported by the second end member in at least a radial direction.

[0010] One example of a suspension system in accordance with the subject matter of the present disclosure can include a pressurized gas system that includes a pressurized gas source and a control device. The suspension system can also include at least one gas spring assembly according to the foregoing paragraph. The at least one gas sprig assembly can be disposed in fluid communication with the pressurized gas source through the control device such that pressurized gas can be selectively transferred into and out of the spring chamber.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] FIG. 1 is a schematic representation of one example of a suspension system of an associated vehicle including a gas spring assembly in accordance with the subject matter of the present disclosure. [0012] FIG. 2 is a side elevation view of one example of a gas spring assembly that includes one example of an end member in accordance with the subject matter of the present disclosure.

[0013] FIG. 3 is a cross-sectional side view of the gas spring assembly in FIG. 2 taken from along line 3-3 in FIG. 2.

[0014] FIG. 4 is an enlarged view of the portion of the gas spring assembly identified in Detail 4 of FIG. 3.

[0015] FIG. 5 is a top perspective view of the exemplary end member shown in FIGS. 2-4 in accordance with the subject matter of the present disclosure.

[0016] FIG. 6 is a bottom perspective view of the exemplary end member shown in FIGS. 2-5.

[0017] FIG. 7 is a top plan view of the exemplary end member shown in FIGS. 2-6.

[0018] FIG. 8 is a bottom plan view of the exemplary end member shown in FIGS. 2- 7.

[0019] FIG. 9 is a side elevation view of the exemplary end member shown in FIGS. 2-8.

[0020] FIG. 10 is a graphical representation illustrating an approximate relationship of force and displacement at a common, constant pressure for a gas spring assembly in accordance with the subject matter of the present disclosure in comparison with a gas spring assembly having a conventional construction.

DETAILED DESCRIPTION

[0021] 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 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.

[0022] FIG. 1 illustrates one example of a suspension system 100 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 axle AXL, 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. Additionally, it will also be appreciated that such a suspension system of the vehicle can also optionally include a plurality of damping members, such as dampers DMP, for example, and that any such damping members can also be operatively connected between the sprung and unsprung masses of the associated vehicle in any suitable manner.

[0023] The suspension system can also include a plurality of gas spring assemblies supported between the sprung and unsprung masses of the associated vehicle. In the arrangement shown in FIG. 1 , suspension system 100 includes four gas spring assemblies 102, one of which is disposed toward each corner of the associated vehicle adjacent a corresponding wheel WHL. However, it will be appreciated that any other suitable number of gas spring assemblies could alternately be used in any other configuration or arrangement. As shown in FIG. 1 , gas spring assemblies 102 are supported between axles AXL and body BDY of associated vehicle VHC. Additionally, it will be recognized that the gas spring assemblies shown and described in FIG. 1 (e.g., gas spring assemblies 102) are illustrated 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.

[0024] Suspension system 100 also includes a pressurized gas system 104 operatively associated with the gas spring assemblies for selectively supplying pressurized gas (e.g., air) thereto and selectively transferring pressurized gas therefrom . In the exemplary embodiment shown in FIG. 1 , pressurized gas system 104 includes a pressurized gas source, such as a compressor 106, for example, for generating pressurized air or other gases. A control device, such as a valve assembly 108, for example, is shown as being in communication with compressor 106 and can be of any suitable configuration or arrangement. In the exemplary embodiment shown, valve assembly 108 includes a valve block 110 with a plurality of valves 112 supported thereon. Valve assembly 108 can also optionally include a suitable exhaust, such as a muffler 114, for example, for venting pressurized gas from the system . Optionally, pressurized gas system 104 can also include a reservoir 116 in fluid communication with the compressor and/or valve assembly 108 and suitable for storing pressurized gas.

[0025] Valve assembly 108 is in communication with gas spring assemblies 102 through suitable gas transfer lines 118. As such, pressurized gas can be selectively transferred into and/or out of the gas spring assemblies through valve assembly 108 by selectively operating valves 112, such as to alter or maintain vehicle height at one or more corners of the vehicle, for example.

[0026] Suspension system 100 can also include a control system 120 that is capable of communication with any one or more systems and/or components (not shown) of vehicle VHC and/or suspension system 100, such as for selective operation and/or control thereof. Control system 120 can include a controller or electronic control unit (ECU) 122 communicatively coupled with compressor 106 and/or valve assembly 108, such as through a conductor or lead 124, for example, for selective operation and control thereof, which can include supplying and exhausting pressurized gas to and/or from gas spring assemblies 102. Controller 122 can be of any suitable type, kind and/or configuration.

[0027] Control system 120 can also, optionally, include one or more height (or distance) sensing devices 126, such as, for example, may be operatively associated with the gas spring assemblies and capable of outputting or otherwise generating data, signals and/or other communications having a relation to a height of the gas spring assemblies or a distance between other components of the vehicle. Such height sensing devices can be in communication with ECU 122, which can receive the height or distance signals therefrom. The height sensing devices can be in communication with ECU 122 in any suitable manner, such as through conductors or leads 128, for example. Additionally, it will be appreciated that the height sensing devices can be of any suitable type, kind and/or construction.

[0028] One example of a gas spring assembly 200 in accordance with the subject matter of the present disclosure, such as may be suitable for use as one of gas spring assemblies 102 in FIG. 1 , for example, is shown in FIGS. 2-4 as having a longitudinally- extending axis AX (FIG. 3) and can include one or more end members, such as an end member 202 and an end member 204 that is spaced longitudinally from end member 202. A flexible spring member 206 can extend peripherally around axis AX and can be secured between the end members in a substantially fluid-tight manner such that a spring chamber 208 (FIG. 3) is at least partially defined therebetween.

[0029] Gas spring assembly 200 can be disposed between associated sprung and unsprung masses of an associated vehicle in any suitable manner. For example, one end member can be operatively connected to the associated sprung mass with the other end member disposed toward and operatively connected to the associated unsprung mass. In the embodiment shown in FIGS. 2 and 3, for example, end member 202 is secured along a first or upper structural component USC, such as associated vehicle body BDY in FIG. 1 , for example, and can be secured thereon in any suitable manner. For example, one or more securement devices, such as mounting studs 210, for example, can be included along end member 202. In some cases, the one or more securement devices (e.g., mounting studs 210) can project outwardly from end member 202 and can be secured thereon in a suitable manner, such as, for example, by way of a flowed-material joint (not shown) or a press-fit connection (not identified). Additionally, such one or more securement devices can extend through mounting holes HLS in upper structural component USC and receive one or more threaded nuts 212 or other securement devices, for example. As an alternative to one or more of mounting studs 210, one or more threaded passages (e.g., blind passages and/or through passages) could be used in conjunction with a corresponding number of one or more threaded fasteners.

[0030] Additionally, a fluid communication port, such as a transfer passage 214 (FIG. 3), for example, can optionally be provided to permit fluid communication with spring chamber 208, such as may be used for transferring pressurized gas into and/or out of the spring chamber, for example. In the exemplary embodiment shown, transfer passage 214 extends through at least one of mounting studs 210 and is in fluid communication with spring chamber 208. It will be appreciated, however, that any other suitable fluid communication arrangement could alternately be used.

[0031] End member 204 can be secured on or along a second or lower structural component LSC, such as an axle AXL in FIG. 1 , for example, in any suitable manner. As one example, lower structural component LSC could include one or more mounting holes HLS extending therethrough. In such case, a threaded fastener 216 could extend through one of mounting holes HLS and threadably engage end member 204 to secure the end member on or along the lower structural component.

[0032] It will be appreciated that the one or more end members can be of any suitable type, kind, construction and/or configuration, and can be operatively connected or otherwise secured to the flexible spring member in any suitable manner. In the exemplary arrangement shown in FIGS. 2 and 3, for example, end member 202 is of a type commonly referred to as a bead plate and is secured to a first end 218 of flexible spring member 206 using a crimped-edge connection 220. End member 204 is shown in the exemplary arrangement in FIGS. 2-4 as being of a type commonly referred to as a piston (or a roll-off piston). A second end 222 of flexible spring member 206 is supported on end member 204 such that a free and/or otherwise unsupported rolling lobe 224 is formed along end member 204 in spaced relation to an outer surface 226 thereof. As gas spring assembly 200 is displaced between extended and collapsed conditions, rolling lobe 224 is axially displaced in a free and/or otherwise unsupported condition relative to end member 204.

[0033] It will be appreciated that flexible spring member 206 can 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 member 206 is shown in FIGS. 2-4 as including a flexible wall 228 that can be formed in any suitable manner and from any suitable material or combination of materials, such as by using one or more fabric- reinforced, elastomeric plies or layers and/or one or more un-reinforced, elastomeric plies or layers, for example. 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.

[0034] Flexible wall 228 can extend in a generally longitudinal direction between opposing first and second ends 218 and 222 of flexible spring member 206. Additionally, flexible wall 228 can include an outer surface 230 and an inner surface 232, which can at least partially define a spring chamber 208. Flexible wall 228 can include an outer or cover ply (not identified) that at least partially forms outer surface 230. Flexible wall 228 can also include an inner or liner ply (not identified) that at least partially forms inner surface 232. In some cases, flexible wall 228 can further include one or more reinforcing plies (not shown) disposed between outer and inner surfaces 230 and 232. 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 approximately equal but opposite bias angle.

[0035] Flexible spring member 206 can include any feature or combination of features suitable for forming a substantially fluid-tight connection with end member 202 and/or end member 204. As one example, flexible spring member 206 can include a mounting bead 234 disposed along end 218 and a mounting bead 236 disposed along end 222. In such cases, the mounting bead, if provided, can, optionally, include a reinforcing element, such as an endless, annular bead wire 238, for example.

[0036] With further reference to FIGS. 2-4 as well as FIGS. 5-9, end member 204 extends generally between a first or upper end 240 and a second or lower end 242. End member 204 can be formed from any suitable material or combination of materials, and can include any suitable number of one or more components. For example, the end member could be formed from two or more metal parts that are secured together, such as by way of one or more securement devices and/or flowed-material joints, for example. As another example, end member 204 could be formed from a polymeric material, and could be molded or otherwise formed as a single, unitary body that includes one or more walls and/or wall portions. As one example, end member 204 can be formed from a substantially rigid polymeric material, 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.

[0037] In the arrangement in FIGS. 2-4 and 5-9, end member 204 is shown as including an end member body 244 formed from one or more end member walls and/or wall portions. It will be appreciated that any suitable combination of walls and/or wall portions can be used in accordance with the subject matter of the present disclosure. For example, end member body 244 of end member 204 is shown as including an outer side wall (or outer side wall portion) 246 that extends in a generally axial direction and peripherally about axis AX. As identified in FIG. 4, outer side wall 246 has an outer surface 248 that can at least partially define an outermost periphery of end member 204. Outer side wall 246 is shown as extending in the axial direction between a shoulder 246A and a distal edge 246B. In some cases, outer side wall 246 can include an inner surface 250 disposed opposite outer surface 248.

[0038] End member body 244 can also include an outer side wall (or outer side wall portion) 252 that extends in a generally axial direction and peripherally about axis AX. Outer side wall 252 can include outer surface 226, as mentioned above, and can, in some cases, have an inner surface 256 disposed opposite outer surface 226. Outer side wall 252 is spaced radially inward from outer side wall 246 such that an annular space or gap is formed therebetween, such as is represented in FIG. 4 by reference dimension GP1 , for example. End member body 244 can further include an end wall (or end wall portion) 258 that is disposed generally transverse to axis AX. End wall 258 can extend annularly about axis AX and radially between outer side walls 246 and 252. In a preferred arrangement, end wall 258 can operatively connect outer side walls 246 and 252 such that outer side wall 246 is substantially-rigidly supported on outer side wall 252. End wall 258 can include a surface 260 facing toward end member 202 and can, optionally, include a surface 262 facing opposite surface 260.

[0039] End member body 244 can include an end wall (or end wall portion) 264 that extends radially inward from outer side wall 252 along end 242 of end member 204. In a preferred arrangement, end wall 264 can at least partially form a mounting surface or mounting plane MP (FIG. 2) along which end member 204 can be secured in abutting engagement with an associated structural component (e.g., lower structural component LSC). End wall 264 can have an outer surface 266 and an inner surface 268 facing opposite the outer surface. In some cases, inner surface 256 of outer side wall 252 and/or inner surface 268 of end wall 264 can at least partially define an end member chamber 270 within end member 204. In some cases, such as is shown in FIG. 3, for example, end member chamber 270 can be disposed in fluid communication with spring chamber 208. In some cases, end member chamber 270 can form a substantially contiguous volume with spring chamber 208. In other cases, one or more fluid flow passages and/or flow control devices can be disposed in fluid communication between end member chamber 270 and spring chamber 208, such as may be beneficial for providing pressurized gas damping, for example.

[0040] End member body 244 can, optionally, include one or more support walls (or support wall portions) or other similar features for providing structural rigidity and/or support to the end member and walls (or wall portions) thereof. For example, end member body 244 can, optionally, include a plurality of support walls (or support wall portions) 272 disposed within end member chamber 270. It will be appreciated that any suitable configuration and/or arrangement of support walls could be used. For example, support walls 272 are shown in FIGS. 3 and 4 as well as in FIGS. 5 and 7 as extending from along outer side wall 252 in a radially-inward direction toward axis AX. Additionally, or in the alternative, support walls 272 can extend from along end wall 264 in an axial direction toward end 240 of end member 204. In the arrangement shown, support walls 272 have an inner edge 274 with a curved profile. It will be appreciated, however, that other configurations and/or arrangements could alternately be used.

[0041] Additionally, or in the alternative, end member body 244 can, optionally, include a plurality of support walls (or support wall portions) 276 disposed along the exterior of the end member body. It will be appreciated that any suitable configuration and/or arrangement of support walls could be used. For example, support walls 276 are shown in FIGS. 3 and 4 as well as in FIGS. 5, 6, 8 and 9 as extending from along outer side wall 252 in a radially-outward direction toward outer side wall 246. Additionally, or in the alternative, support walls 276 can extend from along end wall 258 in an axial direction toward end 242 of end member 204. In the arrangement shown, support walls 276 have an outer edge 278 with a curved profile. It will be appreciated, however, that other configurations and/or arrangements could alternately be used.

[0042] As discussed above, flexible spring member 206 can be secured on or along end member 204 in any suitable manner. As one example, end member body 244 can include a mounting wall (or mounting wall portion) 280 that extends in a generally axial direction from along end wall 258, outer side wall 252 and/or another suitable wall portion toward a distal edge 282. Mounting wall 280 can include an inner surface 284 that can at least partially form an opening (not numbered) through which spring chamber 208 and end member chamber 270 can fluidically communicate. Mounting wall 280 can also include an outer surface 286 that is dimensioned to receive and form a substantially fluid-tight seal with an end (e.g., end 222) of flexible spring member 206. In some cases, one or more projections can extend radially outward from along outer surface 286, such as may be useful to retain or assist in retaining the end of flexible spring member 206 on or along mounting wall 280. In the arrangement shown, an annular projection 288 extends radially outward from along outer surface 286 and peripherally around axis AX.

[0043] It will be appreciated that end member 204 and/or gas spring assembly 200 can include additional features, characteristics and/or components of any suitable type, kind and/or configuration without departing from the subject matter of the present disclosure. For example, end member body 244 can include a central boss or projection 290 that extends axially from along end wall 264 in a direction toward end 240. In some cases, support walls 272, if provided, can be operatively connected with projection 290 in a suitable manner. Additionally, end member 204 can include a securement feature or device suitable for securing the end member on or along the associated structural component (e.g., lower structural component LSC). As one example, end member 204 can include an insert or other component 292 that is at least partially embedded within projection 290. In such case, insert 292 can include a passage with one or more helical threads (not numbered). A securement device, such as threaded fastener 216, for example, can extend through one of mounting holes HLS in the lower structural component and threadably engage insert 292 to secure the end member on or along the lower structural component. It will be appreciated, however, that other configurations and/or arrangements could alternately be used.

[0044] As another example, end member body 244 can, optionally, include a bumper mount 294 or other suitable feature for receiving and retaining a jounce bumper 296 within spring chamber 208 and/or end member chamber 270. In the arrangement shown, bumper mount 294 is disposed along projection 290 and/or along support walls 272. Bumper mount 294 is dimensioned to receive a corresponding mounting feature (not numbered) of jounce bumper 296. As is well understood in the art, jounce bumpers of a wide variety of types, kinds and constructions can be used to inhibit contact between opposing parts during a full jounce (i.e., compressed) condition of the gas spring assembly.

[0045] As a further example, a height or distance sensing device 298 is, optionally, shown in FIG. 3 as being disposed within spring chamber 208 along end member 202 and being secured thereto using suitable fasteners 300. Height sensing device 298 can be of any suitable type, kind and/or construction, such as an ultrasonic sensor that transmits and receives ultrasonic waves WVS (FIG. 3), for example. Additionally, it will be appreciated that height sensing device 298 can be connected to other systems and/or components of a vehicle suspension system in any suitable manner. As shown in FIG. 3, height sensing device 298 includes a lead or connection 302 that can be used for such communication purposes, such as is indicated by leads 128 of control system 120 in FIG. 1 , for example.

[0046] It will be recognized and appreciated that in conventional gas spring constructions, the flexible spring member forms a rolling lobe by rolling and unrolling the flexible spring member in abutting engagement along the outside surface of the end member. The subject construction differs from conventional constructions in that outer surface 226 of outer side wall portion 252 is spaced radially inward from rolling lobe 224. As such, an annular spacing or gap is formed and maintained between outer surface 230 of flexible spring member 206 and outer surface 226 of end member 204, such as is represented in FIG. 4 by reference dimension GP2.

[0047] It has been recognized that, upon being left unsupported, a flexible spring member, such as flexible spring member 206, for example, will attempt to adopt a minimum cross-sectional dimension (e.g., diameter) that approximately corresponds to the original size at which the flexible spring member was constructed. In the present example, flexible spring member 206 is shown as having a minimum cross-sectional dimension represented by reference line MIN. Additionally, it will be recognized and appreciated that outer side wall portion 246 has an outermost dimension that is represented in FIG. 4 by reference dimension OD1 and outer side wall portion 252 has an outside dimension that is represented by reference dimension OD2. It will be further recognized that dimension OD1 is greater than dimension OD2 such that gap GP1 is formed therebetween. Additionally, it will be recognized that minimum cross-sectional dimension MIN, which flexible spring wall 206 has adopted, is less than reference dimension OD1 but greater than reference dimension OD2. As such, it will be appreciated that rolling lobe 224 can be displaced axially relative to end member 204 as gas spring assembly 200 is displaced between extended and compressed conditions while remaining free and unsupported in the radial direction.

[0048] Furthermore, gas spring assembly 200 is constructed such that at a nominal or design height, which is represented in FIG. 2 by reference dimension HT1 , rolling lobe 224 is positioned between end wall portions 258 and 264. In a preferred arrangement, rolling lobe 224 will be disposed in spaced relation to each of end walls in an intermediate position along outer side wall portion 252. As one example, rolling lobe 224 is shown as being disposed in spaced relation to end wall portion 258, as is represented in FIG. 4 by reference dimension DS1 , and in spaced relation to end wall portion 264, as is represented by reference dimension DS2. It will be appreciated that at design height HT1 , dimensions DS1 and DS2 may not be equal. However, in a preferred arrangement, each of dimensions DS1 and DS2 will be greater than or equal to about ten percent (10%) of the maximum cross-sectional dimension of flexible spring member 206, as is represented in FIG. 2 by reference dimension DMX. In a more preferred arrangement, each of dimensions DS1 and DS2 can be greater than or equal to about fifteen percent (15%) of dimension DMX, and in an even more preferred arrangement, each of dimensions DS1 and DS2 can be greater than or equal to about twenty percent (20%) of dimension DMX. [0049] As flexible spring member 206 adopts minimum cross-sectional dimension MIN, a change in cross-sectional dimension from dimension OD1 to dimension MIN is adopted, which is represented in FIG. 4 by reference dimension RD1. Additionally, a corresponding change in position of rolling lobe 224 occurs in comparison with a conventional construction, which is represented in FIG. 4 by dashed lines CCS. Such a change in length is represented in FIG. 4 by reference dimension CD1.

[0050] Furthermore, it has been recognized that allowing flexible spring member 206 to adopt such a configuration with a free and unsupported rolling lobe can result in a reduction in spring rate, as is represented in FIG. 10 by reference dimension CR1.

[0051] 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.

[0052] 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.

[0053] 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.

[0054] 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 that 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.

[0055] 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.