US-12624738-B2 - Methods of manufacturing gas spring end member assemblies and gas spring assemblies including same

Abstract

An end member assembly is dimensioned for securement to an associated flexible spring member. End member assembly includes first, second and third end member sections. First end member section includes a first outer peripheral wall portion. Second end member section includes a second outer peripheral wall portion. Second end member section is positioned in abutting engagement with the first end member section such that a groove extends peripherally around first and second end member sections between first and second outer peripheral wall portions. Third end member section is injection molded in situ with first and second end member sections such that third end member section extends peripherally around first and second end member sections within groove. Gas spring assemblies and vehicle suspension systems are also included.

Inventors

• Michael F. Schweisthal
• Jan van Aartsen
• Pawel Wojtkowiak

Assignees

• FIRESTONE INDUSTRIAL PRODUCTS COMPANY, LLC

Dates

Publication Date

20260512

Application Date

20210211

Claims (19)

1. 1 . A method of manufacturing a gas spring end member assembly, said method comprising: injecting a first quantity of polymeric material into a first mold cavity at least partially defined by first and second first mold sections thereby molding a first end member section having a first section wall that includes a first outer peripheral wall portion; injecting a second quantity of polymeric material into a second mold cavity at least partially defined by first and second second mold sections thereby molding a second end member section that is separate from said first end member section, said second end member section including a second section wall that includes a second outer peripheral wall portion; separating said first first mold section from said second first mold section thereby exposing at least said first outer peripheral wall portion of said first section wall while said first end member section remains in situ in a portion of said first mold cavity of said second first mold section; separating said first second mold section from said second second mold section thereby exposing at least said second outer peripheral wall portion of said second section wall while said second end member section remains in situ in a portion of said second mold cavity of said second second mold section; introducing said first end member section in situ in said portion of said first mold cavity of said second first mold section to said second end member section in situ in said portion of said second mold cavity of said second second mold section thereby forming a groove extending peripherally around said first and second end member sections; and, injecting a third quantity of polymeric material in situ into said groove between said first and second end member sections thereby forming a third end member section operatively connecting said first and second end member sections such that a substantially fluid-tight joint is formed therebetween.
2. 2 . A method according to claim 1 , wherein injecting said first quantity of polymeric material into said first mold cavity at least partially defined by said first and second first mold sections thereby molding said first end member section includes forming said first section wall with a first end surface portion that at least partially defines said groove.
3. 3 . A method according to claim 2 , wherein injecting said first quantity of polymeric material into said first mold cavity at least partially defined by said first and second first mold sections thereby molding said first end member section includes forming said first outer peripheral wall portion with a first outermost peripheral edge such that said first end surface portion extends peripherally inward from along said first outermost peripheral edge.
4. 4 . A method according to claim 2 , wherein injecting said first quantity of polymeric material into said first mold cavity at least partially defined by said first and second first mold sections thereby molding said first end member section includes forming said first section wall with a first annular projection extending axially from along said first end surface portion toward a first distal edge disposed within said groove.
5. 5 . A method according to claim 4 , wherein injecting said third quantity of polymeric material in situ into said groove between said first and second end member sections thereby forming said third end member section includes forming at least a portion of said third end member section peripherally inward of said first annular projection such that at least said portion of said third end member section extends coextensively therewith.
6. 6 . A method according to claim 4 , wherein injecting said third quantity of polymeric material in situ into said groove between said first and second end member sections thereby forming said third end member section includes forming at least a portion of said third end member section peripherally outward of said first annular projection such that at least said portion of said third end member section extends coextensively therewith.
7. 7 . A method according to claim 1 , wherein injecting said second quantity of polymeric material into said second mold cavity at least partially defined by said first and second second mold sections thereby molding said second end member section includes forming said second section wall with a second end surface portion that at least partially defines said groove.
8. 8 . A method according to claim 7 , wherein injecting said second quantity of polymeric material into said second mold cavity at least partially defined by said first and second second mold sections thereby molding said second end member section includes forming said second outer peripheral wall portion with a second outermost peripheral edge such that said second end surface portion extends peripherally inward from along said second outermost peripheral edge.
9. 9 . A method according to claim 7 , wherein injecting said second quantity of polymeric material into said second mold cavity at least partially defined by said first and second second mold sections thereby molding said second end member section includes forming said second section wall with a second annular projection extending axially from along said second end surface portion toward a second distal edge disposed within said groove.
10. 10 . A method according to claim 9 , wherein injecting said third quantity of polymeric material in situ into said groove between said first and second end member sections thereby forming said third end member section includes forming said at least a portion of said third end member section peripherally inward of said second annular projection such that at least said portion of said third end member section extends coextensively therewith.
11. 11 . A method according to claim 9 , wherein injecting said third quantity of polymeric material in situ into said groove between said first and second end member sections thereby forming said third end member section includes forming at least a portion of said third end member section peripherally outward of said second annular projection such that at least said portion of said third end member section extends coextensively therewith.
12. 12 . A method according to claim 1 , wherein injecting said first quantity of polymeric material into said first mold cavity at least partially defined by said first and second first mold sections thereby molding said first end member section includes forming said first section wall with a side surface portion extending around said first end member section along said first outer peripheral wall portion such that said side surface portion at least partially defines a peripherally-inward extent of said groove.
13. 13 . A method according to claim 1 , wherein injecting said first quantity of polymeric material into said first mold cavity at least partially defined by said first and second first mold sections thereby molding said first end member section includes forming said first section wall with a first distal end surface portion, injecting said second quantity of polymeric material into said second mold cavity at least partially defined by said first and second second mold sections thereby molding said second end member section includes forming said second section wall with a second distal end surface portion, and introducing said first end member section in situ in said portion of said first mold cavity of said second first mold section to said second end member section in situ in said portion of said second mold cavity of said second second mold section includes orienting said second distal end surface portion in facing relation to said first distal end surface portion.
14. 14 . A method according to claim 13 , wherein introducing said first end member section in situ in said portion of said first mold cavity of said second first mold section to said second end member section in situ in said portion of said second mold cavity of said second second mold section includes positioning said first and second distal end surface portions in abutting engagement with one another.
15. 15 . A method according to claim 14 , wherein injecting said first quantity of polymeric material into said first mold cavity at least partially defined by said first and second first mold sections thereby molding said first end member section includes forming said first section wall with an alignment groove extending axially into said first outer peripheral wall portion from along said first distal end surface portion, and injecting said second quantity of polymeric material into said second mold cavity at least partially defined by said first and second second mold sections thereby molding said second end member section includes forming said second section wall with an alignment projection extending axially outward from along said second distal end surface, and introducing said first end member section in situ in said portion of said first mold cavity of said second first mold section to said second end member section in situ in said portion of said second mold cavity of said second second mold section includes orienting said second distal end surface portion such that said alignment projection is at least partially received within said alignment groove.
16. 16 . A method according to claim 1 , wherein introducing said first end member section in situ in said portion of said first mold cavity of said second first mold section to said second end member section in situ in said portion of said second mold cavity of said second second mold section includes orienting said first and second end members sections such that an end member chamber is at least partially defined therebetween.
17. 17 . A method according to claim 1 further comprising: providing a flexible spring member extending peripherally about a longitudinal axis and longitudinally between opposing first and second ends such that a spring chamber is at least partially defined therebetween; securing an end member across said first end of said flexible spring member; and, securing said gas spring end member assembly across said second end of said flexible spring member such that a substantially fluid-tight connection is formed therebetween.
18. 18 . A method according to claim 17 , wherein introducing said first end member section in situ in said portion of said first mold cavity of said second first mold section to said second end member section in situ in said portion of said second mold cavity of said second second mold section includes orienting said first and second end member sections together such that an end member chamber is at least partially defined therebetween, and securing said gas spring end member assembly across said second end of said flexible spring member includes connecting said end member chamber in fluid communication with said spring chamber.
19. 19 . A method according to claim 1 further comprising providing at least one third mold section, and operatively engaging said at least one third mold section with one or more of said first first mold section, said second first mold section, said first second mold section and/or said second second mold section to at least partially define a third mold cavity within said groove prior to injecting said third quantity of polymeric material into said third mold cavity.

Description

This application is the National Stage of International Application No. PCT/US2021/017541, filed on Feb. 11, 2021, which claims the benefit of priority from U.S. Provisional Patent Application No. 62/972,967, filed on Feb. 11, 2020, the entire contents of which is hereby incorporated herein by reference. BACKGROUND The subject matter of the present disclosure broadly relates to the art of gas spring devices and, more particularly, to end member assemblies for gas springs that include two polymeric wall portions with a third polymeric wall portion injection molded separately therefrom with the two polymeric wall portions in situ such that a substantially fluid-tight joint is formed by the third polymeric wall portion around, across and/or otherwise between the first and second polymeric wall portions. Gas spring assemblies including one or more of such end member assemblies are also included. In some cases, such gas spring assemblies can be assembled coextensively with a damper to form gas spring and damper assemblies. Additionally, vehicle suspension systems including one or more of such gas spring assemblies (and/or gas spring and damper assemblies) are included. 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 and damper 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 associated with suspension systems of wheeled vehicles. 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. Generally, the plurality of spring devices function to accommodate forces and loads associated with the operation and use of the vehicle. The plurality of damping devices are operative to dissipate energy associated with undesired inputs and movements of the sprung mass, such as road inputs occurring under dynamic operation of a vehicle, for example. In many cases, the damping devices can be liquid-filled, hydraulic dampers of a known construction (e.g., a conventional shock absorber or strut). In other cases, however, the damping devices can be of a type and kind that utilize gaseous fluid rather than liquid as the working medium. In many applications involving vehicle suspension systems, it may be desirable to utilize spring elements that have as low of a spring rate as is practical, as the use of lower spring rate elements can provide improved ride quality and comfort compared to spring elements having higher spring rates. That is, it is well understood in the art that the use of spring elements having higher spring rates (i.e., stiffer springs) will transmit a greater magnitude of road inputs into the sprung mass of the vehicle and that this typically results in a rougher, less-comfortable ride. Whereas, the use of spring elements having lower spring rates (i.e., softer, more-compliant springs) will transmit a lesser amount of road inputs into the sprung mass and will, thus, provide a more comfortable ride. In some cases, the spring devices of vehicle suspension systems will include springs that utilize pressurized gas as the working medium of the devices. Generally, it is 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. This is commonly done by utilizing an end member that defines an additional chamber, cavity or volume filled with pressurized gas in fluid communication with the primary spring chamber of the gas spring. However, end members of this type can be challenging to manufacture as a single unitary component. Thus, in many cases, such end members are assembled from multiple components that are secured together such that a substantially fl