Air intake device for damper with side collector

Abstract

A damper having an inner tube and an outer tube and a piston disposed within the inner tube to define first and second working chambers. A fluid transfer chamber is positioned between the inner and outer tubes. A collector chamber is positioned outside the outer tube. An intake valve assembly abutting one end of the inner tube is positioned inside the outer tube to define a first intermediate chamber arranged in fluid communication with the collector chamber. The intake valve assembly includes a central passage arranged in fluid communication with the second working chamber and one or more intake valves controlling fluid flow through the intake valve assembly between the first intermediate chamber and the central passage and between the first intermediate chamber and the fluid transfer chamber.

Description

[0001] Cross Reference to Related Applications

[0002] This patent application is a continuation-in-part of U.S. Patent Application Serial No. 16 / 515,219, filed July 18, 2019, entitled “Pre-Assembled Piston Accumulator Insert Device,” and claims priority to U.S. Patent Application No. 17 / 324,620, filed May 19, 2021. The entire disclosure of the applications referenced above is hereby expressly incorporated by reference. TECHNICAL FIELD

[0003] The present disclosure relates generally to dampers. More specifically, the present disclosure relates to dampers having multiple external control valves mounted to a side collector. BACKGROUND

[0004] This section provides background information to the present disclosure which is not necessarily prior art.

[0005] Vehicles often include dampers used in conjunction with a suspension system to absorb vibrations that occur when driving the vehicle. To absorb the vibrations, the dampers are typically connected between a body of the vehicle and the suspension system. A piston is located within the damper. The piston is connected to the body of the vehicle or the vehicle suspension by a piston rod. The damper also includes a damper body connected to the suspension system. When the damper is compressed or extended, the piston can restrict the flow of a damping fluid between a first working chamber and a second working chamber defined within the damper body in order to generate a damping force that counteracts the vibrations. By further restricting the flow of the damping fluid between the first working chamber and the second working chamber of the damper, the damper can generate a greater damping force.

[0006] Dampers typically include one or more valves that control the flow of fluid during extension and compression movements of the piston. Current damper designs include a valve block that provides mutual hydraulic connections between the first and second working chambers, the valves, and an accumulator. Such designs often make the damper bulky and increase the overall cost of the damper. Current dampers also have a check valve that further increases the size and cost of the damper. SUMMARY

[0007] This section provides a general summary of the disclosure and not a complete list of the full scope or all features of the application.

[0008] According to one aspect of the present disclosure, a damper is provided. The damper includes an inner tube extending longitudinally between a first inner tube end and a second inner tube end. The damper includes a piston slidably disposed within the inner tube. The piston defines a first working chamber and a second working chamber within the inner tube. The first working chamber is positioned longitudinally between the piston and the first inner tube end, and the second working chamber is positioned longitudinally between the piston and the second inner tube end. The damper further includes an outer tube disposed about the inner tube. The outer tube extends longitudinally between a first outer tube end and a second outer tube end. The first working chamber is arranged in fluid communication with a fluid transfer chamber that is disposed radially between the inner tube and the outer tube. The damper further includes a cover member mounted to the outer tube to define a collector chamber that is positioned exterior to the outer tube.

[0009] The damper includes a gas inlet valve assembly positioned within the outer tube to define a first intermediate chamber that is arranged in fluid communication with the collector chamber. The gas inlet valve assembly includes a central passage that extends longitudinally through the gas inlet valve assembly and is arranged in fluid communication with the second working chamber. The gas inlet valve assembly further includes one or more gas inlet valves that control fluid flow through the gas inlet valve assembly between the first intermediate chamber and the central passage and between the first intermediate chamber and the fluid transfer chamber. For example, during a compression stroke of the damper, at least one gas inlet valve controls fluid flow through the gas inlet valve assembly from the first intermediate chamber to the fluid transfer chamber. During an extension stroke of the damper, at least one gas inlet valve controls fluid flow through the gas inlet valve assembly from the first intermediate chamber to the second working chamber via the central passage.

[0010] According to another aspect of the present disclosure, the damper includes first and second control valves that are externally mounted to the cover member on the outer tube, and the gas inlet valve assembly internally defines first and second intermediate chambers in the outer tube. The first control valve has a first control valve inlet arranged in fluid communication with the fluid transfer chamber via a first control valve port in the outer tube and a first control valve outlet arranged in fluid communication with the collector chamber. The second control valve has a second control valve inlet arranged in fluid communication with the second intermediate chamber of the gas inlet valve assembly via a second control valve port in the outer tube and a second control valve outlet arranged in fluid communication with the collector chamber. According to this arrangement, the first control valve controls the damping level during an extension stroke, and the second control valve controls the damping level during a compression stroke.

[0011] The first and second control valve ports are circumferentially aligned with one another on the outer tube along a control valve port axis that extends parallel to a central longitudinal axis of the damper. The cover member abuts the outer tube along the control valve port axis such that the collector chamber extends on each side of the control valve port axis. The collector chamber is arranged to be in fluid communication with the first intermediate chamber via one or more open ports in the outer tube that are offset relative to the first and second control valve ports such that the one or more open ports are circumferentially spaced apart relative to the control valve port axis. According to this arrangement, the overall packaging height of the first and second control valves is reduced by minimizing the height of the collector chamber in the area where the first and second control valves mate with the first and second control valve ports.

[0012] According to another aspect of the disclosure, a method of manufacturing the disclosed damper is provided. The method includes the steps of inserting the accumulator insert and then inserting the intake valve assembly into the first outer tube end. The intake valve assembly is designed to be inserted in a sequentially ordered stack that includes, in order, a tooth ring, a second spring cup stack, a second intake valve body, a first intake valve body, a first spring cup stack, and an adapter ring. In other words, the tooth ring is the first component of the intake valve assembly to be inserted into the first outer tube end and the adapter ring is the last component of the intake valve assembly to be inserted into the first outer tube end. The method continues with the steps of inserting the inner tube into the first outer tube end and pressing the second inner tube end into contact with the adapter ring of the intake valve assembly such that the intake valve assembly is clamped between the accumulator insert and the second inner tube end. This eliminates the need to mechanically attach the intake valve assembly to the outer tube, such as by welding. The method can also include creating a pre-assembled intake valve assembly by mating the tooth ring, the second spring cup stack, the second intake valve body, the first intake valve body, the first spring cup stack, and the adapter ring onto a holder sleeve prior to inserting the intake valve assembly into the first outer tube end. Thus, both the intake valve assembly and the accumulator insert can be pre-assembled and then slid into the outer tube of the damper. BRIEF DESCRIPTION OF DRAWINGS

[0013] The drawings described herein are for illustrative purposes only of selected embodiments and are not intended to limit the scope of the present disclosure.

[0014] Figure 1 is a diagram of a vehicle incorporating a suspension system constructed in accordance with the present invention;

[0015] Figure 2 is a front perspective view of an exemplary damper constructed in accordance with the present disclosure;

[0016] Figure 3 is Figure 2 is a side cross-sectional view of the exemplary damper shown;

[0017] Figure 4 is Figure 3 an enlarged side cross-sectional view of the exemplary damper shown in FIG. 1, including arrows showing the fluid flow path through the damper during a compression stroke;

[0018] Figure 5 is Figure 3 another enlarged side cross-sectional view of the exemplary damper shown in FIG. 1, including arrows showing the fluid flow path through the damper during an extension stroke;

[0019] Figure 6 is Figure 3 a front exploded perspective view of an exemplary intake valve assembly and accumulator insert of the exemplary damper shown in FIG. 1;

[0020] Figure 7 is Figure 3 a rear exploded perspective view of an exemplary intake valve assembly and accumulator insert of the exemplary damper shown in FIG. 1;

[0021] Figure 8 is a side cross-sectional view of another exemplary damper constructed in accordance with the present disclosure;

[0022] Figure 9 is Figure 8 an enlarged side cross-sectional view of the exemplary damper shown in FIG. 1, including arrows showing the fluid flow path through the damper during a compression stroke;

[0023] Figure 10 is Figure 8 another enlarged side cross-sectional view of the exemplary damper shown in FIG. 1, including arrows showing the fluid flow path through the damper during an extension stroke;

[0024] Figure 11 is Figure 8 a front exploded perspective view of another exemplary intake valve assembly and accumulator insert of the exemplary damper shown in FIG. 1;

[0025] Figure 12 is Figure 8 a rear exploded perspective view of an exemplary intake valve assembly and accumulator insert of the exemplary damper shown in FIG. 1;

[0026] Figure 13 is a front perspective view of another exemplary damper constructed in accordance with the present disclosure;

[0027] Figure 14 is a side cross-sectional view of the exemplary damper shown in FIG. 1 taken along line 14-14; Figure 13

[0028] Figure 15 is​Figure 14 enlarged side cross-sectional view of the exemplary damper shown, including arrows, illustrating fluid flow paths through the damper during a compression stroke;

[0029] Figure 16 Figure 14 another enlarged side cross-sectional view of the exemplary damper shown, including arrows, illustrating fluid flow paths through the damper during an extension stroke;

[0030] Figure 17 is a rear cross-sectional view of the exemplary damper taken along line 17-17 bisecting one of the two externally mounted control valves of the damper; Figure 13

[0031] Figure 18 Figure 13

[0032] Figure 19 Figure 13

[0033] Figure 20 Figure 13

[0034] Figure 21 Figure 13

[0035] Figure 22

[0036] Figure 23 DETAILED DESCRIPTION

[0037] Example embodiments now will be described more fully hereinafter with reference to the accompanying drawings. Like

[0038] ​​​​​​​​​​​​Exemplary embodiments now will be described more fully hereinafter with reference to the accompanying drawings. Exemplary embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. Those skilled in the art will recognize, however, that embodiments can be practiced without the specific details given herein. That is, exemplary embodiments can be practiced in a variety of ways, and that the scope of the present disclosure is not limited to one or more specific embodiments provided herein. In some exemplary embodiments, well-known structures, devices, and techniques have not been described in detail so as not to obscure the disclosure.

[0039] The terminology used herein is for the purpose of describing particular exemplary embodiments only and is not intended to be limiting. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," "including," and "having" are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order

[0040] When an element or layer is referred to as being "on," "engaged to," "connected to," or "coupled to" another element or layer, it can be directly on, engaged, connected, or coupled to the other element or layer, or intervening elements or layers can be present. In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to," or "directly coupled to" another element or layer, there are no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0041] Although the terms "first," "second," "third," etc. can be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms can be only used to distinguish one element, component, region, layer or section from another region, layer or section. Unless the context clearly indicates otherwise, as used herein, the terms such as "first," "second," and the like can not imply a sequence or an order, but they can be used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

[0042] For ease of description, spatial relative terms, such as "inner," "outer," "beneath," "below," "lower," "above," "upper," and the like, can be used herein to describe the relationship of one element or feature to another element or feature as shown in the figures. Unless otherwise indicated, the spatial relative terms can be intended to encompass different orientations of the device in use or operation, in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the example term "below" can encompass both an orientation of above and below. The device can be otherwise oriented (rotated 90 degrees or viewed in other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0043] Figure 1 An example vehicle 100 incorporating a suspension system 102 according to the present disclosure is shown. The vehicle 100 can be powered by an internal combustion engine, an electric motor, a hybrid / electric powertrain, or the like. The vehicle 100 includes a vehicle body 104. The suspension system 102 of the vehicle 100 includes a rear suspension 106 and a front suspension 108. The rear suspension 106 includes a laterally extending rear axle assembly (not shown) adapted to operatively support a pair of rear wheels 110. The rear axle assembly is operatively connected to the vehicle body 104 by a pair of dampers 112 and a pair of coil springs 114. Similarly, the front suspension 108 includes a laterally extending front axle assembly (not shown) that supports a pair of front wheels 116. The front axle assembly is connected to the vehicle body 104 by another pair of dampers 112 and a pair of coil springs 118. In alternative embodiments, the vehicle 100 can include independent suspension units (not shown) for each of the four corners instead of the front and rear axle assemblies.

[0044] The dampers 112 of the suspension system 102 are used to dampen the relative motion of the unsprung portion (i.e., the front suspension 108 and the rear suspension 106 and the front wheels 116 and the rear wheels 110) and the sprung portion (i.e., the vehicle body 104) of the vehicle 100. Although the vehicle 100 is depicted as a passenger car, the dampers 112 can be used with other types of vehicles. Examples of such vehicles include buses, trucks, off-road vehicles, three-wheeled vehicles, ATVs, motorcycles, and the like. Furthermore, the term "damper" as used herein is intended to refer to a damper in general and will include shock absorbers, MacPherson struts, as well as semi-active and active suspensions.

[0045] To automatically adjust each of the dampers 112, the electronic controller 120 is electrically connected to the dampers 112. The electronic controller 120 is used to control the operation of each of the dampers 112 in order to provide the appropriate damping characteristics resulting from the motion of the vehicle body 104 of the vehicle 100. The electronic controller 120 can independently control each of the dampers 112 in order to independently control the damping level of each of the dampers 112. The electronic controller 120 can be electrically connected to the dampers 112 via a wired connection, a wireless connection, or a combination thereof.

[0046] The electronic controller 120 can independently adjust the damping level, damping rate, or damping characteristics of each of the dampers 112 to optimize the ride performance of the vehicle 100. As used herein, the term "damping level" refers to the damping force generated by each damper 112 to counteract the motion or vibration of the vehicle body 104. A higher damping level can correspond to a greater damping force. Similarly, a lower damping level can correspond to a smaller damping force. Adjustment of the damping level is beneficial during braking and cornering of the vehicle 100 to counteract brake dive during braking and vehicle body roll during cornering. According to one embodiment of the present disclosure, the electronic controller 120 processes input signals from one or more sensors (not shown) of the vehicle 100 in order to control the damping level of each of the dampers 112. The sensors can sense one or more parameters of the vehicle 100 such as, but not limited to, displacement, velocity, acceleration, vehicle speed, steering wheel angle, brake pressure, engine torque, engine revolutions per minute (RPM), throttle pedal position, and the like. The electronic controller 120 can also control the damping level of the dampers 112 based on the driving mode of the vehicle 100. The driving modes can include a sport mode and a comfort mode. A button (not shown) can allow the driver of the vehicle 100 to select the driving mode of the vehicle 100. The electronic controller 120 can receive input signals based on actuation of the button and control the dampers 112 accordingly.

[0047] According to another embodiment of the present disclosure, the electronic controller 120 controls the damping level of each of the dampers 112 based on external road conditions, such as rain, snow, mud, etc. In another embodiment, the electronic controller 120 adjusts the damping level of each of the dampers 112 based on internal vehicle conditions, such as fuel level, vehicle occupancy, load, etc.

[0048] Although the present disclosure is shown with a single electronic controller 120, it is within the scope of the present disclosure to utilize a dedicated electronic controller for each of the dampers 112. The dedicated electronic controller can be located on each respective damper 112. Alternatively, the electronic controller 120 can be integrated into an electronic control unit (ECU) of the vehicle 100. The electronic controller 120 can include a processor, a memory, an input / output (I / O) interface, a communication interface, and other electronic components. The processor can execute various instructions stored in the memory for performing various operations of the electronic controller 120. The electronic controller 120 can receive and transmit signals and data through the I / O interface and the communication interface. In another embodiment, the electronic controller 120 can include a microcontroller, an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), etc.

[0049] Figure 2 and Figure 3 An exemplary damper 112 is shown. The damper 112 can be any one of the four dampers 112 of the vehicle 100. The damper 112 can optionally be configured as a continuously variable semi-active suspension system damper 112. The damper 112 contains a fluid. By way of example and not limitation, the fluid is a hydraulic fluid or oil. The damper 112 includes an inner tube 122 extending longitudinally between a first inner tube end 156 and a second inner tube end 157. A piston 124 is slidably disposed within the inner tube 122. The piston 124 defines a first working chamber 126 and a second working chamber 128 within the inner tube 122. Each of the first working chamber 126 and the second working chamber 128 contains the fluid therein. The first working chamber 126 is longitudinally positioned between the piston 124 and the first inner tube end 156 and acts as a rebound chamber during movement of the piston 124. The second working chamber 128 is longitudinally positioned between the piston 124 and the second inner tube end 157 and acts as a compression chamber. The volumes of the first working chamber 126 and the second working chamber 128 vary based on movement of the piston 124. The piston 124 is sealed against an interior of the inner tube 122.

[0050] In the illustrated example, the piston 124 is devoid of orifices or passages such that there is no flow of fluid through the piston 124. In other words, fluid in the first working chamber 126 cannot pass through the piston 124 into the second working chamber 128 and vice versa. However, alternative configurations are possible in the event that the piston 124 includes a valve (not shown) to limit high internal pressures within the first working chamber 126 and the second working chamber 128.

[0051] The damper 112 includes a piston rod 134. The piston rod 134 is coaxially aligned with and defines the longitudinal axis A. One end of the piston rod 134 is connected to and reciprocates with the piston 124, while the opposite end of the piston rod 134 includes an attachment fitting 135a that is configured to be connected to a component of the suspension system 102 or the body 104 of the vehicle 100.

[0052] The damper 112 further includes an outer tube 136 annularly disposed about the inner tube 122 and includes an inner cylindrical surface 129 facing and spaced apart from the inner tube 122. In some embodiments, the outer tube 136 is concentrically disposed about the inner tube 122. The outer tube 136 extends longitudinally between a first outer tube end 137 and a second outer tube end 139. The piston rod 134 extends longitudinally outwardly through the first outer tube end 137. The outer tube 136 includes a closed portion 145 at the second outer tube end 139 and a cylindrical portion 147 extending from the first outer tube end 137 to the closed portion 145 at the second outer tube end 139. Optionally, an attachment fitting 135b is mounted to the closed portion 145 of the outer tube 136. The attachment fitting 135b is provided in the form of a hole, a loop, a threaded post, or other attachment structure and is configured to be attached to a component of the suspension system 102 or the body 104 of the vehicle 100.

[0053] The damper 112 further includes a fluid transfer chamber 138 disposed between the inner tube 122 and the outer tube 136. The piston rod 134 extends longitudinally through a guide rod 141 that is housed within the first outer tube end 137. In the illustrated embodiment, the entire guide rod 141 is received within the first outer tube end 137, while only a portion of the guide rod 141 is received within the first inner tube end 156. The guide rod 141 includes a guide rod passage 143 that is arranged in fluid communication with and extends between the first working chamber 126 and the fluid transfer chamber 138. In other words, the fluid transfer chamber 138 is arranged in fluid communication with the first working chamber 126 via the guide rod passage 143.

[0054] Further, the damper 112 includes a cover member 148 attached to the outer tube 136. A collector chamber 152 is defined between the cover member 148 and the outer tube 136. The collector chamber 152 is positioned exteriorly (i.e., radially outwardly) of the outer tube 136.

[0055] In the illustrated example, the collector chamber 152 has a limited circumferential extent that extends around the outer tube in an arc 149 that is less than or equal to 180 degrees. In other words, in the illustrated example, the collector chamber 152 is a pocket that extends along one side of the outer tube 136, and can therefore be distinguished from an annular chamber, such as an annular chamber formed by another tube disposed around the outer tube 136. The outer tube 136 has an outer tube length OL measured longitudinally between a first outer tube end 137 and a second outer tube end 139, and the collector chamber 152 has a collector chamber length CL measured longitudinally between a first collector end 151 and a second collector end 153. The collector chamber length CL is shorter than the outer tube length OL. In other words, the collector chamber 152 is shorter than the outer tube 136, and does not extend along the entire length of the outer tube 136. The four ports 140, 142, 144, 146 extend through the outer tube 136 at longitudinally spaced locations that are aligned with the collector chamber 152 (i.e., positioned within the collector chamber length CL).

[0056] The damper 112 also includes an intake valve assembly 154 having an adapter ring 130 that is press fit into the second inner tube end 157. The adapter ring 130 can be made in different variants having different outer diameters, such that a standardized intake valve assembly 154 can be fitted in dampers having inner tubes 122 of different diameters. The intake valve assembly 154 is disposed inside the outer tube 136, and includes a first intake valve body 155a that abuts the adapter ring 130, a second valve body 155b that is longitudinally spaced from the first intake valve body 155a, and a bulkhead body 155c that is longitudinally positioned between the first intake valve body 155a and the second intake valve body 155b. The intake valve assembly 154 also includes a spacer 150 that is longitudinally positioned between the second intake valve body 155b and the bulkhead body 155c.

[0057] The first intake valve body 155a and the second intake valve body 155b, and the bulkhead body 155c, abut the inner cylindrical surface 129 of the outer tube 136 to define first and second intermediate chambers 159a, 159b inside the outer tube 136. The first intermediate chamber 159a is longitudinally positioned between the first intake valve body 155a and the bulkhead body 155c. The second intermediate chamber 159b is longitudinally positioned between the second intake valve body 155b and the bulkhead body 155c. The accumulation chamber 162 is longitudinally positioned between the second intake valve body 155b and the second outer tube end 139. The first intake valve body 155a forms a partition between the first intermediate chamber 159a and the fluid delivery chamber 138, the second intake valve body 155b forms a partition between the second intermediate chamber 159b and the accumulation chamber 162, and the bulkhead body 155c forms a partition between the first intermediate chamber 159a and the second intermediate chamber 159b.

[0058] While other configurations are possible, in the illustrated example, each of the first intake valve body 155a and the second intake valve body 155b, as well as the bulkhead body 155c, has a cylindrical hub portion and a disc-shaped flange, such that the first intake valve body 155a and the second intake valve body 155b, as well as the bulkhead body 155c, have a similar shape to the top hat. The first intake valve body 155a and the second intake valve body 155b, as well as the bulkhead body 155c, can be pre-assembled prior to insertion into the damper 112 by fasteners 169, such as bolts or rivets, clamping the first intake valve body 155a and the second intake valve body 155b, as well as the bulkhead body 155c, together.

[0059] The first intermediate chamber 159a and the accumulation chamber 162 are each arranged in fluid communication with the collector chamber 152 via ports 144, 146 in the outer tube 136. Reference is made additionally to Figure 6 and Figure 7 The first intake valve body 155a includes a first set of passages 158a and a first set of intake orifices 158b extending through the first intake valve body 155a. The first set of intake orifices 158b is arranged circumferentially (i.e., radially outwardly) around the first set of passages 158a. The bulkhead body 155c includes a second set of passages 158c. The first set of passages 158a in the first intake valve body 155a is aligned with and arranged in fluid communication with the second set of passages 158c in the bulkhead body 155c. Accordingly, fluid can flow between the second intermediate chamber 159b and the second working chamber 128 via the first set of passages 158a and the second set of passages 158c. The second intake valve body 155b includes a second set of intake orifices 158d extending through the second intake valve body 155b.

[0060] The first set of intake orifices 158b allow fluid communication between the first intermediate chamber 159a and the fluid delivery chamber 138. The intake valve assembly 154 further includes a first intake valve 165a that controls fluid flow between the first intermediate chamber 159a and the fluid delivery chamber 138 through the first set of intake orifices 158b. In the illustrated example, the first intake valve 165a is a passive valve. More specifically, in the illustrated embodiment, the first intake valve 165a includes a first spring cup stack 167a mounted to the first intake valve body 155a. In operation, the first spring cup stack 167a opens and closes the first set of intake orifices 158b by flexing toward and away from the first intake valve body 155a based on a pressure differential between the first intermediate chamber 159a and the fluid delivery chamber 138. The first intake valve 165a acts as a one-way valve that permits fluid flow in only one direction from the first intermediate chamber 159a to the fluid delivery chamber 138. As will be explained in greater detail below, this one-way flow through the first intake valve 165a occurs during the compression stroke in which the piston 124 moves toward the intake valve assembly 154.

[0061] The second set of intake orifices 158d allow fluid communication between the accumulation chamber 162 and the second intermediate chamber 159b. The intake valve assembly 154 further includes a second intake valve 165b that controls fluid flow between the accumulation chamber 162 and the second intermediate chamber 159b through the second set of intake orifices 158d. In the illustrated example, the second intake valve 165b is a passive valve. More specifically, in the illustrated embodiment, the second intake valve 165b includes a second spring cup stack 167b mounted to the second intake valve body 155b. In operation, the second spring cup stack 167b opens and closes the second set of intake orifices 158d by flexing toward and away from the second intake valve body 155b based on a pressure differential between the accumulation chamber 162 and the second intermediate chamber 159b. The second intake valve 165b acts as a one-way valve that permits fluid flow in only one direction from the accumulation chamber 162 and the second intermediate chamber 159b. As will be explained in greater detail below, this one-way flow through the second intake valve 165b occurs during the extension stroke in which the piston 124 moves away from the intake valve assembly 154. Optionally, the intake valve assembly 154 can have one or more permanent air bleed passages. For example, the intake valve assembly 154 can include additional slotted cups (not shown) between the first and second spring cup stacks 167a, 167b and the first and second intake valve bodies 155a, 155b. Alternatively, small notches (not shown) can be provided in the sealing base of the first and second intake valve bodies 155a, 155b.

[0062] According to the illustrated embodiment, the damper 112 includes an accumulator insert 160 disposed within the second outer tube end 139. The accumulator insert 160 includes an accumulator sleeve 166, a floating piston 161, and a pressurized chamber (e.g., a gas chamber) 163. The accumulator sleeve 166 is positioned inside the outer tube 136 and extends between a closed end 173 adjacent the second outer tube end 139 and an open end 174 adjacent the intake valve assembly 154. The floating piston 161 is pre-assembled inside the accumulator sleeve 166 in a sliding fit. The pressurized chamber 163 is sealed from the accumulation chamber 162 by the floating piston 161. Thus, the accumulation chamber 162 is longitudinally positioned between the intake valve assembly 154 and the floating piston 161, and at least a portion of the accumulation chamber 162 is disposed inside the accumulator sleeve 166. The accumulator chamber 162 contains a fluid and is arranged to be in fluid communication with the collector chamber 152 via a third port (i.e., an accumulator port) 144 in the outer tube and a hole 175 in the accumulator sleeve 166 that is arranged to be in fluid communication with the third port / accumulator port 144 (i.e., the hole 175 in the accumulator sleeve 166 is aligned with the third port / accumulator port 144 in the outer tube 136). It should be understood that, as used herein, the term hole is intended to include a bore, a port, a passage, a slot, a cutout, or other structure capable of communicating fluid between the accumulation chamber 162 and the collector chamber 152. The pressurized chamber 163 is longitudinally positioned between the floating piston 161 and the closed end 173. The pressurized chamber 163 contains a pressurized fluid, such as a gas, that operates to bias the floating piston 161 toward the intake valve assembly 154.

[0063] The accumulator sleeve 166 extends longitudinally between the second outer tube end 139 and the intake valve assembly 154 such that the closed end 173 of the accumulator sleeve 166 abuts (i.e., contacts) the closed portion 145 of the second outer tube end 139 and such that the open end 174 of the accumulator sleeve 166 abuts the second intake valve body 155b of the intake valve assembly 154. Optionally, the closed end 173 of the accumulator sleeve 166 can be configured to have a shallower curvature than the closed portion 145 of the second outer tube end 139 to form an annular contact area between the closed end 173 of the accumulator sleeve 166 and the closed portion 145 of the second outer tube end 139. This annular contact area serves to help center the accumulator insert 160 within the second outer tube end 139, provide a greater load bearing surface area to support pre-load forces on point contact, and help prevent rotation between the accumulator sleeve 166 and the outer tube 136 by increasing friction on point contact.

[0064] The accumulator sleeve 166 is arranged in a sliding fit within the outer tube 136 and exerts a preload on the intake valve assembly 154 such that the intake valve assembly 154 is clamped between the open end 174 of the accumulator sleeve 166 and the second inner tube end 157 of the inner tube 122. This preload also prevents the accumulator sleeve 166 from rotating relative to the outer tube 136 such that the alignment of the bore 175 in the accumulator sleeve 166 with the third port / accumulator port 144 in the outer tube 136 is maintained after assembly. According to this arrangement, the first and second intake valve bodies 155a, 155b and the bulkhead body 155c do not need to be mechanically attached to the outer tube 136 (such as by welding) as the intake valve assembly 154 is held in place by the accumulator sleeve 166 and the inner tube 122. Instead, the O-ring seals 176 positioned on the first and second intake valve bodies 155a, 155b and the bulkhead body 155c are arranged in sealing contact with the inner cylindrical surface 129 of the outer tube 136.

[0065] According to this embodiment, the manufacture and assembly of the damper 112 is less complex, more efficient and more economical. Both the intake valve assembly 154 and the accumulator insert 160 can be pre-assembled before being mounted inside the outer tube 136. By way of example and not limitation, when the floating piston 161 is inserted into the open end 174 of the accumulator sleeve 166, the pressurized chamber 163 can be charged with pressurized gas at a pressure of 3 to 8 bar. The indentation 179 can then be applied to the accumulator sleeve 166 to prevent the pressurized gas in the pressurized chamber 163 from pushing the floating piston 161 out through the open end 174 in the accumulator sleeve 166. The entire pre-assembled accumulator insert 160 can then be inserted into the outer tube 136. Next, the entire pre-assembled intake valve assembly 154 can be inserted into the outer tube 136. Finally, the inner tube 122 can be inserted into the outer tube 136 until the second inner tube end 157 contacts the adapter ring 130 of the intake valve assembly 154, the piston 124 and the piston rod 134 can be inserted into the inner tube 122, and the guide rod 141 can then be pressed into the first inner tube end 156 and the first outer tube end 137 under a preload. By way of example and not limitation, a preload force of approximately 10 kiloNewtons (kN) can be used. All of these steps can be accomplished without any welding operations.

[0066] For example, an exemplary method of manufacturing damper 112 is set forth below. The method begins with the steps of forming outer tube 136 having first outer tube end 137 and second outer tube end 139, the first outer tube end being open and the second outer tube end having a closed portion 145; forming inner tube 122 having first inner tube end 156 and second inner tube end 157; and forming a pre-assembled intake valve assembly 154. The step of forming a pre-assembled intake valve assembly 154 includes fastening first intake valve body 155a and second intake valve body 155b to a bulkhead body 155c, which can be accomplished using bolts, rivets, or other fasteners. The method also includes the steps of forming an accumulator sleeve 166 having a closed end 173 and an open end 174; filling accumulator sleeve 166 with pressurized gas; and inserting a floating piston 161 into open end 174 of accumulator sleeve 166 to form a pre-assembled accumulator insert 160. The method can also include the steps of forming accumulator port 144 in outer tube 136 and collector chamber 152, which is arranged in fluid communication with accumulator port 144; forming hole 175 in accumulator sleeve 166, which is arranged in fluid communication with accumulator port 144 by aligning hole 175 with accumulator port 144; and forming indent 179 in accumulator sleeve 166 after the step of inserting floating piston 161 into open end 174 of accumulator sleeve 166 to prevent pressurized gas in pressurized chamber 163 from pushing floating piston 161 out through open end 174 of accumulator sleeve 166.

[0067] The method then continues with the steps of inserting pre-assembled accumulator insert 160 into first outer tube end 137; inserting pre-assembled intake valve assembly 154 into first outer tube end 137; and inserting inner tube 122 into first outer tube end 137. Piston 124 and piston rod 134 are inserted into inner tube 122 and guide rod 141 is pressed into first inner tube end 156 and first outer tube end 137 at a predetermined pre-load, which presses second inner tube end 157 into contact with adapter ring 130 of intake valve assembly 154, presses pre-assembled intake valve assembly 154 into contact with open end 174 of accumulator sleeve 166, and presses closed end 173 of accumulator sleeve 166 into contact with closed portion 145 of second outer tube end 139. According to the method, all welding, heat treating, and painting operations on outer tube 136 are completed prior to the steps of inserting pre-assembled intake valve assembly 154 and pre-assembled accumulator insert 160 into outer tube 136.

[0068] There are multiple advantages associated with the present design. First, it is easier to fill the pressurized chamber 163 with pressurized gas when the accumulator insert 160 is outside of the damper 112 than it is to fill the second outer tube end 139 with pressurized gas, which typically requires a separate fill port or welded end cap on the second outer tube end 139. Second, the present design also makes it easier to coat the outer tube 136 with paint / coating that requires high temperature curing by moving the floating piston 161 into the accumulator insert subassembly 160, as the typical seals used on the floating piston 161 cannot withstand high temperatures. Third, it is possible to weld attachment fittings such as attachment fitting 135b and cap member 148 to the outer tube 136 without affecting the sealing surface of the floating piston 161, as the floating piston 161 slides against the inner surface of the accumulator sleeve 166 rather than the inner cylindrical surface 129 of the outer tube 136. Heat generated by welding operations can cause distortion and create changes (i.e., alterations) in the part geometry, which can adversely affect the operation and sealing of the floating piston 161. The presently disclosed design solves this problem as no welding operations are required on the accumulator sleeve along the travel path of the floating piston 161, and all welding operations on the outer tube 136 are completed prior to inserting the accumulator insert 160 into the outer tube 136.

[0069] The damper 112 includes a first control valve 164a and a second control valve 164b mounted externally to the outer tube 136. In the illustrated example, the first and second control valves 164a, 164b are two-position solenoid actuated electro-hydraulic valves. However, it should be appreciated that other types of active (e.g., electric) or passive (e.g., mechanical) externally mounted valves can be used. As will be explained in greater detail below, the first control valve 164a is operable to regulate fluid flow from the fluid delivery chamber 138 to the collector chamber 152, and the second control valve 164b is operable to regulate fluid flow from the second intermediate chamber 159b to the collector chamber 152. The first control valve 264a includes a first valve member 171a that is movable along a first control valve axis VA1 between an open position and a closed position. The second control valve 264b includes a second valve member 171b that is movable along a second control valve axis VA2 between an open position and a closed position. Although other configurations are possible, in the illustrated embodiment, the first and second control valve axes VA1, VA2 are parallel to each other and longitudinally spaced apart, and arranged perpendicular to the longitudinal axis A of the piston rod 134.

[0070] The electronic controller 120 can adjust the first control valve 164a and the second control valve 164b to control the damping level of the damper 112. The first control valve 164a and the second control valve 164b can be controlled by input current provided to the solenoids of the first control valve 164a and the second control valve 164b. The electronic controller 120 generates the input current to control the operation and damping level of the damper 112. The solenoids of the first control valve 164a and the second control valve 164b can be electrically connected to the electronic controller 120. Further, the input current can vary between a lower limit and an upper limit, which correspond to the minimum and maximum limit positions (i.e., open and closed positions) of the first control valve 164a and the second control valve 164b. The electronic controller 120 can control the damping force or level by controlling the degree of restriction of the first control valve 164a and the second control valve 164b. Specifically, the electronic controller 120 can adjust the input current to vary the restriction of the first control valve 164a and the second control valve 164b. Sending low current to the first control valve 164a and the second control valve 164b can correspond to a low damping ratio or damping level. Similarly, sending high current to the first control valve 164a and the second control valve 164b can correspond to a high damping ratio or damping level.

[0071] The first control valve 164a has a first control valve inlet 170a arranged in fluid communication with the fluid transfer chamber 138 between the inner tube 122 and the outer tube 136, and a first control valve outlet 172a arranged in fluid communication with the collector chamber 152. The first port 140 in the outer tube 136 is arranged in fluid communication with and extends between the fluid transfer chamber 138 and the first control valve inlet 170a.

[0072] The second control valve 164b has a second control valve inlet 170b arranged in fluid communication with the second intermediate chamber 159b and a second control valve outlet 172b arranged in fluid communication with the collector chamber 152. The second port 142 in the outer tube 136 is arranged in fluid communication with and extends between the second intermediate chamber 159b and the second control valve inlet 170b. The third port 144 in the outer tube 136 is arranged in fluid communication with and extends between the collector chamber 152 and the accumulator chamber 162. The fourth port 146 in the outer tube 136 is arranged in fluid communication with and extends between the collector chamber 152 and the first intermediate chamber 159a. Thus, the accumulator chamber 162 is arranged in fluid communication with the collector chamber 152 via the third port 144 in the outer tube 136, and the first intermediate chamber 159a is arranged in fluid communication with the collector chamber 152 via the fourth port 146 in the outer tube 136.

[0073] During the extension (i.e., rebound) stroke of damper 112, first control valve 164a is operable to regulate fluid flow from fluid delivery chamber 138 to collector chamber 152 in response to movement of piston 124 toward guide rod 141. During the extension stroke of damper 112, first control valve 164a is in the open position to control the rebound damping characteristics of damper 112. Specifically, the opening degree of first control valve 164a can be adjusted to adjust the extension / rebound damping characteristics of damper 112. During the extension stroke of damper 112, second control valve 164b is in the closed position. Therefore, during the extension stroke, there is no direct fluid communication between the second intermediate chamber 159b and collector chamber 152.

[0074] During the compression stroke, the second control valve 164b is operable to regulate fluid flow from the second intermediate chamber 159b to the collector chamber 152 in response to movement of the piston 124 toward the intake valve assembly 154. The second control valve 164b is in the open position during the compression stroke of the damper 112 to control the compression damping characteristics of the damper 112. Specifically, the opening degree of the second control valve 164b can be adjusted to adjust the compression damping characteristics of the damper 112. During the compression stroke of the damper 112, the first control valve 164a is in the closed position. Therefore, during the compression stroke, there is no direct fluid communication between the fluid delivery chamber 138 and the collector chamber 152.

[0075] In the illustrated example, each of the first control valve 164a and the second control valve 164b includes control valve housings 168a, 168b. A portion of each control valve housing 168a, 168b is received within and extends through a cover member 148. Although the first port 140 and the second port 142 in the outer tube 136 are... Figure 2 The hole is shown as a round hole, but the shape and size of the first port 140 and the second port 142 in the outer tube 136 may be based on any shape and size of the control valve housings 168a and 168b.

[0076] In the open position, the first control valve 164a allows fluid communication between the fluid delivery chamber 138 and the collector chamber 152. More specifically, the first control valve inlet 170a is in fluid communication with the fluid delivery chamber 138, and the first control valve outlet 172a is in fluid communication with the collector chamber 152. The first valve member 171a allows selective fluid communication between the first control valve inlet 170a and the first control valve outlet 172a, and thus allows selective fluid flow between the fluid delivery chamber 138 and the collector chamber 152, which ultimately regulates the fluid flow from the first working chamber 126 to the accumulation chamber 162.

[0077] In the open position, the second control valve 164b allows fluid communication between the first intermediate chamber 159a and the accumulator chamber 152. More specifically, the second control valve inlet 170b is in fluid communication with the first intermediate chamber 159a, and the second control valve outlet 172b is in fluid communication with the accumulator chamber 152. The second valve member 171b allows selective fluid communication between the second control valve inlet 170b and the second control valve outlet 172b, and thus, selective fluid flow between the first intermediate chamber 159a and the accumulator chamber 152, which ultimately regulates fluid flow from the second working chamber 128 to the accumulation chamber 162.

[0078] The intake valve assembly 154 allows bi-directional flow of fluid between the accumulation chamber 162 and the second working chamber 128. During a compression stroke, the volume of the first working chamber 126 increases as the piston 124 moves toward the intake valve assembly 154. The first intake valve 165a in the intake valve assembly 154 provides a compensating fluid flow, where fluid from the second control valve outlet 172b flows into the accumulator chamber 152, through the fourth port 146 in the outer tube 136, through the first intermediate chamber 159a, through the first set of intake orifices 158b in the first intake valve body 155a, into the fluid transfer chamber 138, and ultimately into the first working chamber 126 to increase the amount of fluid in the first working chamber 126. During an extension / rebound stroke, the volume of the first working chamber 126 decreases as the piston 124 moves away from the intake valve assembly 154. The second intake valve 165b in the intake valve assembly 154 provides a compensating fluid flow, where fluid in the accumulation chamber 162 flows through the intake valve assembly 154 and into the second working chamber 128 to increase the amount of fluid in the second working chamber 128.

[0079] The operation of the damper 112 during rebound and compression strokes will now be explained in more detail.

[0080] Referring to Figure 4 , the damper 112 is shown in a compression stroke, which occurs as the piston 124 moves toward the intake valve assembly 154. During the compression stroke, the volume of fluid in the first working chamber 126 displaced by the piston rod 134 increases and the volume of the second working chamber 128 decreases. Additional fluid flow is supplied to the first working chamber 126 to compensate for the increase in volume of the first working chamber 126. Furthermore, during the compression stroke, there is a net flow of fluid into the accumulation chamber 162, which causes the floating piston 161 to move away from the intake valve assembly 154, thereby increasing the size of the accumulation chamber 162. This net flow of fluid into the accumulation chamber 162 occurs due to the increase in volume of the piston rod 134 in the first working chamber 126.

[0081] During the compression stroke, the first control valve 164a is in the closed position, the second control valve 164b is in the open position, and the piston 124 moves toward the intake valve assembly 154. A compression flow path Pl is defined within the damper 112, where the fluid in the second working chamber 128 flows through the first set of passages 158a in the first intake valve body 155a, through the second set of passages 158c in the isolation wall body 155c, and into the second intermediate chamber 159b. The fluid in the second intermediate chamber 159b flows toward the second control valve inlet 170b and through the second port 142 in the outer tube 136. From the second control valve inlet 170b, the fluid flows toward the second control valve outlet 172b because the second control valve 164b is in the open position and the fluid from the second control valve outlet 172b flows into the collector chamber 152. The fluid flowing into the collector chamber 152 flows into the accumulation chamber 162 via the third port 144 in the outer tube 136 and into the first intermediate chamber 159a via the fourth port 146. If the pressure differential between the first intermediate chamber 159a and the fluid transfer chamber 138 exceeds the burst pressure of the first intake valve 165a, the first intake valve 165a will open and fluid will flow through the first set of intake orifices 158b in the first intake valve body 155a, through the fluid transfer chamber 138, and into the first working chamber 126 through the guide rod passage 143, which increases the volume during the compression stroke.

[0082] With reference to Figure 5 , the damper 112 is shown in the extension / rebound stroke, which occurs as the piston 124 moves away from the intake valve assembly 154. During the extension / rebound stroke, the volume of fluid in the first working chamber 126 displaced by the piston rod 134 decreases, and the volume of fluid in the second working chamber 128 increases. Additional fluid flow is supplied to the second working chamber 128 to compensate for the increase in volume of the second working chamber 128. To increase the amount of fluid in the second working chamber 128, some portion of the fluid from the accumulation chamber 162 flows through the intake valve assembly 154 and into the second working chamber 128, such that an extension flow path P2 is defined within the damper 112. In addition, during the extension / rebound stroke, there is a net flow of fluid out of the accumulation chamber 162, which causes the floating piston 161 to move toward the intake valve assembly 154, thereby decreasing the size of the accumulation chamber 162. This net flow of fluid out of the accumulation chamber 162 occurs due to the decrease in volume of the piston rod 134 in the first working chamber 126.

[0083] During the extension / rebound stroke, the first control valve 164a is in the open position, the second control valve 164b is in the closed position, and the piston 124 moves away from the intake valve assembly 154. Fluid in the first working chamber 126 flows into the fluid transfer chamber 138 via the guide rod passage 143. The fluid in the fluid transfer chamber 138 then flows to the first control valve inlet 170a and through the first port 140 in the outer tube 136. The fluid from the first control valve inlet 170a flows to the first control valve outlet 172a because the first control valve 164a is in the open position, and the fluid from the first control valve outlet 172a flows into the collector chamber 152. The fluid from the collector chamber 152 flows into the accumulation chamber 162 via the third port 144 in the outer tube 136. Finally, the fluid in the accumulation chamber 162 flows through the intake valve assembly 154 and into the second working chamber 128. When the pressure differential between the accumulation chamber 162 and the second intermediate chamber 159b exceeds the burst pressure of the second intake valve 165b, the second intake valve 165b will open, and the fluid in the accumulation chamber 162 will flow through the second set of intake orifices 158d in the second intake valve body 155b, through the second intermediate chamber 159b, through the second set of passages 158c in the isolation wall body 155c, through the first set of passages 158a in the first intake valve body 155a, and into the second working chamber 128, which increases the volume during the extension / rebound stroke.

[0084] Figure 8 and Figure 9 Another example damper 112' is shown having an alternative configuration of an intake valve assembly 154'. Figure 8 and Figure 9 Many of the elements of the damper 112' shown are the same as those of the damper 112 shown in FIGS. 1-3 and, as such, share the same reference numbers. Figure 2 and Figure 3 The elements of the damper 112' shown that are new, different, or modified are labeled with reference numbers in which a prime (' ) notation has been appended after the figure number. Figure 8 and Figure 9 The elements of the damper 112' shown that are new, different, or modified are labeled with reference numbers in which a prime (' ) notation has been appended after the figure number.

[0085] The intake valve assembly 154' is disposed inside the outer tube 136 and includes a first intake valve body 155a', a second valve body 155b', and an isolation wall body 155c' that abut the adapter ring 130. According to this alternative arrangement, the second valve body 155b' is positioned longitudinally between the first intake valve body 155a' and the isolation wall body 155c'. The intake valve assembly 154' also includes a spacer 150' that is positioned longitudinally between the second intake valve body 155b' and the isolation wall body 155c'.

[0086] The first intake valve body 155a' and the second intake valve body 155b' and the bulkhead body 155c' abut the inner cylindrical surface 129 of the outer tube 136 to define first and second intermediate chambers 159a' and 159b' inside the outer tube 136. The first intermediate chamber 159a' is longitudinally positioned between the first intake valve body 155a' and the second intake valve body 155b'. The second intermediate chamber 159b' is longitudinally positioned between the second intake valve body 155b' and the bulkhead body 155c'. The accumulation chamber 162' is longitudinally positioned between the bulkhead body 155c' and the second outer tube end 139. The first intake valve body 155a' forms a partition between the first intermediate chamber 159a' and the fluid transfer chamber 138, the second intake valve body 155b' forms a partition between the first intermediate chamber 159a' and the second intermediate chamber 159b', and the bulkhead body 155c' forms a partition between the second intermediate chamber 159b' and the accumulation chamber 162'.

[0087] According to this embodiment, the damper 112' includes an accumulator insert 160' disposed within the second outer tube end 139. The accumulator insert 160' includes an accumulator sleeve 166', a floating piston 161, and a pressurized chamber (e.g., a gas chamber) 163. The accumulator sleeve 166' is positioned inside the outer tube 136 and extends between a closed end 173 adjacent the second outer tube end 139 and an open end 174' adjacent the intake valve assembly 154'. The floating piston 161 is pre-assembled inside the accumulator sleeve 166' in a sliding fit. The pressurized chamber 163 is sealingly partitioned from the accumulation chamber 162' by the floating piston 161. Thus, the accumulation chamber 162' is longitudinally positioned between the intake valve assembly 154' and the floating piston 161, and at least a portion of the accumulation chamber 162' is disposed inside the accumulator sleeve 166'. The accumulator chamber 162' contains a fluid and is arranged to be in fluid communication with the collector chamber 152 via a third port (i.e., an accumulator port) 144 in the outer tube 136 and a plurality of holes 175' in the accumulator sleeve 166' arranged to be in fluid communication with the third port / accumulator port 144. The pressurized chamber 163 is longitudinally positioned between the floating piston 161 and the closed end 173. The pressurized chamber 163 contains a pressurized fluid, such as a gas, which operates to bias the floating piston 161 toward the intake valve assembly 154'.

[0088] The accumulator sleeve 166' extends longitudinally between the second outer tube end 139 and the intake valve assembly 154' such that the closed end 173 of the accumulator sleeve 166' abuts (i.e., contacts) the closed portion 145 of the second outer tube end 139 and such that the open end 174' of the accumulator sleeve 166 abuts the bulkhead body 155c' of the intake valve assembly 154'. Again, the accumulator sleeve 166' is disposed in a sliding fit within the outer tube 136 and exerts a preload on the intake valve assembly 154' such that the intake valve assembly 154' is clamped between the open end 174' of the accumulator sleeve 166' and the second inner tube end 157 of the inner tube 122. According to this arrangement, the first and second intake valve bodies 155a', 155b' and the bulkhead body 155c' do not need to be mechanically attached (such as by welding) to the outer tube 136 because the intake valve assembly 154' is held in place by the accumulator sleeve 166' and the inner tube 122. O-ring seals 176' positioned on the first and second intake valve bodies 155a', 155b' and the bulkhead body 155c' are arranged in sealing contact with the inner cylindrical surface 129 of the outer tube 136.

[0089] According to this embodiment, the open end 174' of the accumulator sleeve 166' has an inwardly tapered edge 177'. This inwardly tapered edge 177' has a frusto-conical shape such that an annular gap 178' is formed between the inwardly tapered edge 177' and the inner cylindrical surface 129 of the outer tube 136. This annular gap 178' is longitudinally aligned with and arranged in fluid communication with the accumulator port / third port 144 in the outer tube 136. The bore 175' in the accumulator sleeve 166' is positioned at circumferentially spaced locations along the inwardly tapered edge 177' such that fluid in the accumulation chamber 162' can flow into the annular gap 178' and through the accumulator port / third port 144 in the outer tube 136, or in the opposite direction, from the collector chamber 152 to the accumulation chamber 162'. Thus, this arrangement eliminates the need to ensure alignment between the bore 175, 175' and the accumulator port / third port 144 in the outer tube 136. Furthermore, the inwardly tapered edge 177' serves to retain the floating piston 161 inside the accumulator sleeve 166' after the pressurized chamber 163 has been filled (i.e., charged) with pressurized gas.

[0090] Damper 112' can be manufactured using the same methods described above, but with the following additional steps after the step of inserting floating piston 161 into open end 174' of accumulator sleeve 166': forming an inwardly tapered edge 177' at open end 174' of accumulator sleeve 166', rather than forming a dimple 179 in accumulator sleeve 166. This step of forming inwardly tapered edge 177' prevents pressurized gas in accumulator insert 160' from pushing floating piston 161 out through open end 174' of accumulator sleeve 166'. Further, the step of forming hole 175' in accumulator sleeve 166' can include forming a plurality of holes 175' at circumferentially spaced apart locations in inwardly tapered edge 177'.

[0091] While other configurations are possible, in the illustrated example, each of first intake valve body 155a' and second intake valve body 155b' has a cylindrical hub portion and a disc-shaped flange, such that first intake valve body 155a' and second intake valve body 155b' have a similar shape to a top hat. In this configuration, isolation wall body 155c' is shaped like a solid disc. In this embodiment, there are no orifices or passages in isolation wall body 155c'. Thus, isolation wall body 155c' acts as a fluid flow impediment, such that there is no fluid flow through isolation wall body 155c'. First intake valve body 155a' and second intake valve body 155b' and isolation wall body 155c' can be pre-assembled prior to insertion into damper 112' by fasteners 169' (such as bolts or rivets) that clamp first intake valve body 155a' and second intake valve body 155b' and isolation wall body 155c' together.

[0092] First intermediate chamber 159a' and accumulation chamber 162 are each arranged to be in fluid communication with collector chamber 152 via third port 144 and fourth port 146 in outer tube 136. Reference is made additionally to Figure 11 and Figure 12The first intake valve body 155a' includes a first set of passages 158a' and a first set of intake orifices 158b' extending through the first intake valve body 155a'. The first set of intake orifices 158b' are arranged circumferentially (i.e., radially outwardly) around the first set of passages 158a'. The second intake valve body 155b' includes a second set of intake passages 158c' and a second set of intake orifices 158d' extending through the second intake valve body 155b'. The second set of intake orifices 158d' are arranged circumferentially (i.e., radially outwardly) around the second set of passages 158c'. The first set of passages 158a' in the first intake valve body 155a' are aligned with and arranged in fluid communication with the second set of passages 158c' in the second intake valve body 155b'. Accordingly, fluid can flow between the second intermediate chamber 159b' and the second working chamber 128' via the first set of passages 158a' and the second set of passages 158c'.

[0093] The first set of intake orifices 158b' allow fluid communication between the first intermediate chamber 159a' and the fluid transfer chamber 138. The intake valve assembly 154' further includes a first intake valve 165a' that controls fluid flow between the first intermediate chamber 159a' and the fluid transfer chamber 138 through the first set of intake orifices 158b'. In the illustrated example, the first intake valve 165a' is a passive valve. More specifically, in the illustrated embodiment, the first intake valve 165a' includes a first spring cup stack 167a' that is mounted to the first intake valve body 155a'. In operation, the first spring cup stack 167a' opens and closes the first intake orifices 158b' by flexing toward and away from the first intake valve body 155a' based on a pressure differential between the first intermediate chamber 159a' and the fluid transfer chamber 138. The first intake valve 165a' acts as a one-way valve that permits fluid flow in only one direction from the first intermediate chamber 159a' to the fluid transfer chamber 138. As will be explained in greater detail below, this one-way flow through the first intake valve 165a' occurs during a compression stroke in which the piston 124 is moved toward the intake valve assembly 154'.

[0094] The second set of intake orifices 158d' allow fluid communication between the first intermediate chamber 159a' and the second intermediate chamber 159b'. The intake valve assembly 154' further includes a second intake valve 165b' that controls fluid flow between the first intermediate chamber 159a' and the second intermediate chamber 159b' through the second set of intake orifices 158d'. In the illustrated example, the second intake valve 165b' is a passive valve. More specifically, in the illustrated embodiment, the second intake valve 165b' includes a second spring cup stack 167b' mounted to the second intake valve body 155b'. In operation, the second spring cup stack 167b' opens and closes the second intake orifices 158d' by flexing toward and away from the second intake valve body 155b' based on a pressure differential between the first intermediate chamber 159a' and the second intermediate chamber 159b'. The second intake valve 165b' acts as a one-way valve that permits fluid flow in only one direction from the first intermediate chamber 159a' and the second intermediate chamber 159b'. As will be explained in greater detail below, this one-way flow through the second intake valve 165b' occurs during the extension stroke in which the piston 124 moves away from the intake valve assembly 154'.

[0095] The intake valve assembly 154' allows for bi-directional flow of fluid between the accumulation chamber 162 and the second working chamber 128. During the compression stroke, the volume of the first working chamber 126 increases as the piston 124 moves toward the intake valve assembly 154'. The first intake valve 165a' in the intake valve assembly 154' provides a compensating fluid flow in which fluid from the second control valve outlet 172b flows into the collector chamber 152, through the fourth port 146 in the outer tube 136, through the first intermediate chamber 159a', through the first set of intake orifices 158b' in the first intake valve body 155a', into the fluid transfer chamber 138, and ultimately into the first working chamber 126 to increase the amount of fluid in the first working chamber 126. During the extension / rebound stroke, the volume of the first working chamber 126 decreases as the piston 124 moves away from the intake valve assembly 154'. The second intake valve 165b' in the intake valve assembly 154' provides a compensating fluid flow in which fluid in the accumulation chamber 162 flows through the intake valve assembly 154' and into the second working chamber 128 to increase the amount of fluid in the second working chamber 128.

[0096] The operation of the damper 112' during the rebound and compression strokes will now be explained in greater detail.

[0097] Reference is made to Figure 9Damper 112' is shown in the compression stroke, which occurs as piston 124 moves toward intake valve assembly 154'. During the compression stroke, the volume of fluid in first working chamber 126 displaced by piston rod 134 increases and the volume of second working chamber 128 decreases. Additional fluid flow is supplied to first working chamber 126 to compensate for the increase in volume of first working chamber 126. Further, during the compression stroke, there is a net flow of fluid into accumulation chamber 162, which causes floating piston 161 to move away from intake valve assembly 154', increasing the size of accumulation chamber 162. This net flow of fluid into accumulation chamber 162 occurs due to the increase in volume of piston rod 134 in first working chamber 126.

[0098] During the compression stroke, first control valve 164a is in the closed position, second control valve 164b is in the open position, and piston 124 moves toward intake valve assembly 154'. Compression flow path P1' is defined inside damper 112', where fluid in second working chamber 128 flows through first set of passages 158a' in first intake valve body 155a', through second set of passages 158c' in second intake valve body 155b', and into second intermediate chamber 159b'. Fluid in second intermediate chamber 159b' flows toward second control valve inlet 170b and through second port 142 in outer tube 136. Fluid from second control valve inlet 170b flows toward second control valve outlet 172b because second control valve 164b is in the open position and fluid from second control valve outlet 172b flows into collector chamber 152. Fluid from collector chamber 152 flows into accumulation chamber 162 via third port 144 in outer tube 136 and into first intermediate chamber 159a' via fourth port 146. If the pressure differential between first intermediate chamber 159a' and fluid transfer chamber 138 exceeds the burst pressure of first intake valve 165a', first intake valve 165a' will open and fluid will flow through first set of intake orifices 158b' in first intake valve body 155a', through fluid transfer chamber 138, and into first working chamber 126 through guide rod passage 143, which increases the volume during the compression stroke.

[0099] Referring to Figure 10During the extension / rebound stroke, the volume of fluid in the first working chamber 126 displaced by the piston rod 134 decreases, and the volume of fluid in the second working chamber 128 increases. Additional fluid flow is supplied to the second working chamber 128 to compensate for the increase in volume of the second working chamber 128. To increase the amount of fluid in the second working chamber 128, some portion of the fluid from the accumulation chamber 162 flows through the intake valve assembly 154' and into the second working chamber 128, such that an extension flow path P2' is defined within the damper 112'. Additionally, during the extension / rebound stroke, there is a net flow of fluid out of the accumulation chamber 162, which causes the floating piston 161 to move toward the intake valve assembly 154', thereby decreasing the size of the accumulation chamber 162. This net flow of fluid out of the accumulation chamber 162 occurs due to the decrease in volume of the piston rod 134 in the first working chamber 126.

[0100] During the extension / rebound stroke, the first control valve 164a is in the open position, the second control valve 164b is in the closed position, and the piston 124 moves away from the intake valve assembly 154'. The fluid in the first working chamber 126 flows into the fluid delivery chamber 138 via the guide rod passage 143. The fluid in the fluid delivery chamber 138 then flows toward the first control valve inlet 170a and through the first port 140 in the outer tube 136. The fluid from the first control valve inlet 170a flows toward the first control valve outlet 172a because the first control valve 164a is in the open position, and the fluid from the first control valve outlet 172a flows into the collector chamber 152. The fluid from the collector chamber 152 flows into the accumulation chamber 162 via the third port 144 in the outer tube 136 and into the first intermediate chamber 159a' via the fourth port 146. When the pressure differential between the first intermediate chamber 159a' and the second intermediate chamber 159b' exceeds the cracking pressure of the second intake valve 165b', the second intake valve 165b' will open, and the fluid in the first intermediate chamber 159a' will flow through the second set of intake orifices 158d' in the second intake valve body 155b', through the second intermediate chamber 159b', through the second set of passages 158c' in the second intake valve body 155b', through the first set of passages 158a' in the first intake valve body 155a', and into the second working chamber 128, which increases the volume during the extension / rebound stroke.

[0101] It should be understood that in this embodiment, the first intake valve body 155a' and the second intake valve body 155b' are structurally identical and are arranged inside the outer tube 136 only with opposite orientations, such that the first intake valve 165a' is positioned on the side of the first intake valve body 155a' closer to the piston 124, and the second intake valve 165b' is positioned on the side of the second intake valve body 155b' closer to the accumulation chamber 162. Because the first intake valve body 155a' and the second intake valve body 155b' are structurally identical, this arrangement reduces the manufacturing cost of the intake valve assembly 154' compared to an intake valve assembly 154 in which the first intake valve body 155a and the second intake valve body 155b need to be manufactured as two different components.

[0102] Figures 13 to 21 Another exemplary damper 112 is shown, which has an alternatively configured intake valve assembly 154. Figures 13 to 21 The damper 112" shown has many components and Figures 2 to 12 The dampers 112 and 112' shown have the same or similar elements and therefore share the same reference numerals, which are followed by double apostrophes (").

[0103] Figure 13 and Figure 14 Another exemplary damper 112 is shown. The damper 112 can be assembled as follows: Figure 1 The vehicle 100 shown is equipped with any one of four dampers 112. The damper 112" includes an inner tube 122" extending longitudinally between a first inner tube end 156" and a second inner tube end 157". A piston 124" is slidably disposed within the inner tube 122". The piston 124" defines a first chamber 126" and a second chamber 128" within the inner tube 122". Each of the first chamber 126" and the second chamber 128" contains hydraulic fluid / oil. The first chamber 126" is longitudinally positioned between the piston 124" and the first inner tube end 156" and acts as a springback chamber during the movement of the piston 124". The second chamber 128" is longitudinally positioned between the piston 124" and the second inner tube end 157" and acts as a compression chamber. The volumes of the first chamber 126" and the second chamber 128" vary based on the movement of the piston 124".

[0104] In the illustrated example, the piston 124" seals the interior of the inner tube 122" and is free of orifices or passages such that there is no fluid flow through the piston 124". In other words, fluid in the first working chamber 126" cannot pass through the piston 124" into the second working chamber 128" and vice versa. However, alternative configurations are possible in the event that the piston 124" can include a valve (not shown) to limit high internal pressures within the first working chamber 126" and the second working chamber 128".

[0105] The damper 112" includes a piston rod 134". The piston rod 134" is coaxially aligned with and defines the central longitudinal axis A of the damper 112". One end of the piston rod 134" is connected to and reciprocates with the piston 124", while the opposite end of the piston rod 134" includes an attachment fitting 135a" configured to be connected to a component of the suspension system 102 or the body 104 of the vehicle 100 as shown. Figure 1

[0106] The damper 112" further includes an outer tube 136" annularly disposed about the inner tube 122". The outer tube 136" includes an inner cylindrical surface 129" and an outer cylindrical surface 131" opposite the inner cylindrical surface 129". The inner cylindrical surface 129" faces and is spaced apart from the inner tube 122". In some embodiments, the outer tube 136" is concentrically disposed about the inner tube 122" such that both the inner tube 122" and the outer tube 136" are coaxially aligned with the central longitudinal axis A of the damper 112". The outer tube 136" extends longitudinally between a first outer tube end 137" and a second outer tube end 139". The piston rod 134" extends longitudinally outwardly through the first outer tube end 137". The outer tube 136" includes a closed portion 145" at the second outer tube end 139" and a cylindrical portion 147" extending from the first outer tube end 137" to the closed portion 145" at the second outer tube end 139". Optionally, a spring perch 200" is mounted to the outer tube 136" at a location adjacent the first outer tube end 137" and annularly extends therefrom. The spring perch 200" can be provided to configure the damper 112" such that it can be used as shown for a front wheel 116 of the vehicle 100 as shown, with the spring perch 200" supporting Figure 1 Figure 1 one end of the spring 118 as shown.

[0107] ​​Damper 112” also includes a fluid transfer chamber 138” disposed between inner tube 122” and outer tube 136”. Piston rod 134” extends longitudinally through a rod guide 141” positioned at first outer tube end 137”. A portion of rod guide 141” cooperates with first outer tube end 137” and first inner tube end 156”. Inside of rod guide 141”, first inner tube end 156” contains one or more openings 202” that provide fluid communication between first working chamber 126” and fluid transfer chamber 138”. In other words, fluid transfer chamber 138” is arranged to be in fluid communication with first working chamber 126” via openings 202” in first inner tube end 156”.

[0108] Damper 112” also includes a cap member 148” attached to outer cylindrical surface 131” of outer tube 136”. By way of example and without limitation, cap member 148” can be welded to outer cylindrical surface 131” of outer tube 136”. A collector chamber 152” is defined between cap member 148” and outer tube 136”. Thus, according to this arrangement, collector chamber 152” is positioned outside (i.e., radially outward) of outer tube 136”. Optionally, a fill fitting 203” can be provided on cap member 148” to provide a location where collector chamber 152” can be filled or refilled with hydraulic fluid or oil.

[0109] First and second control valves 164a” and 164b” are externally mounted to cap member 148” on outer tube 136”. The operation of first and second control valves 164a” and 164b” will be explained in greater detail below, but at a high level, first and second control valves 164a” and 164b” regulate two fluid flow paths that can deliver fluid into and out of collector chamber 152”. First control valve 264a” has a first control valve axis VA1 and second control valve 264b” has a second control valve axis VA2. First and second control valve axes VA1 and VA2 are parallel to each other and longitudinally spaced apart, are circumferentially aligned with each other along a control valve alignment axis AA, and are arranged perpendicular to central longitudinal axis A and control valve alignment axis AA. In other words, first and second control valve axes VA1 and VA2 both intersect central longitudinal axis A and control valve alignment axis AA.

[0110] In the illustrated example, the collector chamber 152" has a limited circumferential extent that extends around the outer tube in an arc 149" that is less than or equal to 180 degrees. In other words, the collector chamber 152" in the illustrated example extends longitudinally along the outer tube 136 on each side of the control valve alignment axis AA. The outer tube 136" has an outer tube length OL measured longitudinally between a first outer tube end 137" and a second outer tube end 139", and the collector chamber 152" has a collector chamber length CL measured longitudinally between a first collector end 151" and a second collector end 153". The collector chamber length CL is shorter than the outer tube length OL. In other words, the collector chamber 152" is shorter than the outer tube 136" and does not extend along the entire length of the outer tube 136".

[0111] With continued reference to Figure 14 The damper 112" includes an intake valve assembly 154" disposed inside the outer tube 136" and including an adapter ring 130", a first intake valve body 155a" abutting the adapter ring 130", a second valve body 155b" abutting the first intake valve body 155a", a bulkhead body 155c", and a tooth ring 155d" longitudinally positioned between the second intake valve body 155b" and the bulkhead body 155c" in an abutting arrangement. The adapter ring 130" is press fit onto the second inner tube end 157", while the first intake valve body 155a" and the second intake valve body 155b" and the bulkhead body 155c" abut the inner cylindrical surface 129" of the outer tube 136" to define first and second intermediate chambers 159a" and 159b" inside the outer tube 136".

[0112] The first intermediate chamber 159a" is longitudinally positioned between the first intake valve body 155a" and the second intake valve body 155b", and the second intermediate chamber 159b" is longitudinally positioned between the second intake valve body 155b" and the bulkhead body 155c". The accumulation chamber 162" is longitudinally positioned between the bulkhead body 155c" and the second outer tube end 139". Thus, the first intake valve body 155a" forms a partition between the first intermediate chamber 159a" and the fluid transfer chamber 138", the second intake valve body 155b" forms a partition between the first intermediate chamber 159a" and the second intermediate chamber 159b", and the bulkhead body 155c" forms a partition between the second intermediate chamber 159b" and the accumulation chamber 162".

[0113] The intake valve assembly 154" further includes a first intake valve 165a" mounted to the first intake valve body 155a", a second intake valve 165b" mounted to the second intake valve body 155b", and a central passage 158a" extending longitudinally through the adapter ring 130", the first intake valve body 155a", the second intake valve body 155b", and the tooth ring 155d". Thus, the central passage 158a" extends longitudinally through the intake valve assembly 154" and is arranged in fluid communication with the second working chamber 128" and the second intermediate chamber 159b". The first intake valve 165a" controls fluid flow through the intake valve assembly 154" between the first intermediate chamber 159a" and the fluid transfer chamber 138", while the second intake valve 165b" controls fluid flow through the intake valve assembly 154" between the first intermediate chamber 159a" and the second intermediate chamber 159b", which leads to the central passage 158a" and ultimately to the second working chamber 128".

[0114] According to the illustrated embodiment, the damper 112" includes an accumulator insert 160" disposed within the second outer tube end 139". The accumulator insert 160" includes an accumulator sleeve 166", a floating piston 161", and a pressurized chamber (e.g., a gas chamber) 163". The accumulator sleeve 166" is positioned inside the outer tube 136" and extends between a closed end 173" adjacent the second outer tube end 139" and an open end 174" adjacent the intake valve assembly 154". The floating piston 161" is pre-assembled inside the accumulator sleeve 166" in a sliding fit. The pressurized chamber 163" is separated from the accumulation chamber 162" by the floating piston 161". Thus, the accumulation chamber 162" is longitudinally positioned between the intake valve assembly 154" and the floating piston 161", and the pressurized chamber 163" is longitudinally positioned between the floating piston 161" and the closed end 173". The pressurized chamber 163" contains a pressurized fluid (such as a gas) that operates to bias the floating piston 161" toward the intake valve assembly 154".

[0115] The accumulator sleeve 166” extends longitudinally between the second outer tube end 139” and the intake valve assembly 154” such that the closed end 173” of the accumulator sleeve 166” abuts (i.e., contacts) the closed portion 145” of the second outer tube end 139” and such that the open end 174” of the accumulator sleeve 166” abuts the bulkhead body 155c” of the intake valve assembly 154” such that the intake valve assembly 154” is clamped between the open end 174” of the accumulator sleeve 166” and the second inner tube end 157” of the inner tube 122”. According to this arrangement, the first and second intake valve bodies 155a”, 155b” and the bulkhead body 155c” do not need to be mechanically attached to the outer tube 136” (such as by welding) because the intake valve assembly 154” is held in place by the accumulator sleeve 166” and the inner tube 122”.

[0116] With additional reference to Figure 15 and Figure 16 The first control valve 164a” has a first control valve inlet 170a” arranged in fluid communication with the fluid transfer chamber 138” between the inner tube 122” and the outer tube 136” and a first control valve outlet 172a” arranged in fluid communication with the collector chamber 152”. The first control valve port 140” in the outer tube 136” is arranged in fluid communication with and extends between the fluid transfer chamber 138” and the first control valve inlet 170a”. The second control valve 164b” has a second control valve inlet 170b” arranged in fluid communication with the second intermediate chamber 159b” and a second control valve outlet 172b” arranged in fluid communication with the collector chamber 152”. The second control valve port 142” in the outer tube 136” is arranged in fluid communication with and extends between the second intermediate chamber 159b” and the second control valve inlet 170b”. Thus, the first control valve 164a” regulates fluid flow from the fluid transfer chamber 138” to the collector chamber 152” and the second control valve 164b” regulates fluid flow from the second intermediate chamber 159b” to the collector chamber 152”.

[0117] One or more accumulator ports 144" in the outer tube 136" are arranged in fluid communication with and extending between the collector chamber 152" and the accumulation chamber 162", while one or more open ports 146" in the outer tube 136" are arranged in fluid communication with and extending between the collector chamber 152" and the first intermediate chamber 159a". In other words, the accumulator chamber 162" is arranged in fluid communication with the collector chamber 152" via the accumulator ports 144" in the outer tube 136", and the first intermediate chamber 159a" is arranged in fluid communication with the collector chamber 152" via the open ports 146" in the outer tube 136". The accumulator ports 144" and the open ports 146" in the outer tube 136" are provided in the form of apertures, slots, or holes that are not opened or closed by valves. As a result, fluid can flow freely between the collector chamber 152" and the accumulation chamber 162", and between the collector chamber 152" and the first intermediate chamber 159a".

[0118] In the open position, the first control valve 164a" allows fluid communication between the fluid delivery chamber 138" and the collector chamber 152". More specifically, the first control valve inlet 170a" is in fluid communication with the fluid delivery chamber 138", and the first control valve outlet 172a" is in fluid communication with the collector chamber 152". The first valve member 171a allows selective fluid communication between the first control valve inlet 170a" and the first control valve outlet 172a", and thus selective fluid flow between the fluid delivery chamber 138" and the collector chamber 152", which ultimately regulates fluid flow from the first working chamber 126" to the second working chamber 128".

[0119] In the open position, the second control valve 164b" allows fluid communication between the second intermediate chamber 159b" and the collector chamber 152". More specifically, the second control valve inlet 170b" is in fluid communication with the second intermediate chamber 159b", and the second control valve outlet 172b" is in fluid communication with the collector chamber 152". The second valve member 171b" allows selective fluid communication between the second control valve inlet 170b" and the second control valve outlet 172b", and thus selective fluid flow between the second intermediate chamber 159b" and the collector chamber 152", which ultimately regulates fluid flow from the second working chamber 128" to both the fluid delivery chamber 138" and the accumulation chamber 162".

[0120] As Figure 15As shown, the volume of the second working chamber 128" decreases as the piston 124" moves toward the intake valve assembly 154" during the compression stroke. The second control valve 164b" is actuated to an open position during the compression stroke of the damper 112" to regulate fluid flow from the second intermediate chamber 159b" to the collector chamber 152". Specifically, the opening of the second control valve 164b" can be adjusted to adjust the compression damping characteristics of the damper 112". At the same time, the first control valve 164a" is in a closed position during the compression stroke of the damper 112". Thus, during the compression stroke, there is no communication of fluid directly between the fluid transfer chamber 138" and the collector chamber 152".

[0121] During the compression stroke, a compression flow path P1 is defined inside the damper 112", where fluid in the second working chamber 128" flows through the central passage 158a" in the first intake valve assembly 154" and into the second intermediate chamber 159b". The fluid in the second intermediate chamber 159b" flows toward the second control valve inlet 170b" and through the second control valve port 142" in the outer tube 136". From the second control valve inlet 170b", the fluid flows toward the second control valve outlet 172b" because the second control valve 164b" is in an open position and the fluid from the second control valve outlet 172b" flows into the collector chamber 152". The fluid flowing into the collector chamber 152" flows into the accumulation chamber 162" via the accumulation port 144" in the outer tube 136" and into the first intermediate chamber 159a" via the open port 146" in the outer tube 136". If the pressure differential between the first intermediate chamber 159a" and the fluid transfer chamber 138" exceeds the break pressure of the first intake valve 165a", the first intake valve 165a" will open and fluid will flow through the first set of intake orifices 158b" in the first intake valve body 155a" and into the fluid transfer chamber 138". Some of the fluid in the fluid transfer chamber 138" then flows through the opening 202" in the first inner tube end 156" and into the first working chamber 126", the volume of which increases during the compression stroke. In addition, during the compression stroke, the volume of fluid displaced by the piston rod 134" increases as a greater length of the piston rod 134" moves into the first working chamber 126". The fluid displaced by the piston rod 134" (i.e., rod volume) flows into the collector chamber 152", through the accumulator port 144", and into the accumulation chamber 162", which causes the floating piston 161" to move away from the intake valve assembly 154", thereby increasing the size of the accumulation chamber 162".

[0122] As Figure 16As shown, as the piston 124" moves away from the intake valve assembly 154" during the extension / rebound stroke, the volume of fluid in the second working chamber 128" increases. The first control valve 164a" is actuated to an open position during the extension stroke of the damper 112" to regulate fluid flow from the fluid transfer chamber 138" to the collector chamber 152". Specifically, the opening of the first control valve 164a" can be adjusted to adjust the extension / rebound damping characteristics of the damper 112". At the same time, the second control valve 164b" is in a closed position during the extension stroke of the damper 112". Thus, during the extension stroke, there is no communication of fluid directly between the second intermediate chamber 159b" and the collector chamber 152".

[0123] During the extension / rebound stroke, a rebound flow path P2 is defined inside the damper 112", where fluid in the first working chamber 126" flows into the fluid transfer chamber 138" via the opening 202" in the first inner tube end 156", and the fluid in the fluid transfer chamber 138" then flows to the first control valve inlet 170a" and through the first control valve port 140" in the outer tube 136". Fluid from the first control valve inlet 170a" flows to the first control valve outlet 172a" because the first control valve 164a" is in an open position, and fluid from the first control valve outlet 172a" flows into the collector chamber 152". Fluid from the collector chamber 152" flows into the first intermediate chamber 159a" via the open port 146" in the outer tube 136". When the pressure differential between the first intermediate chamber 159a" and the second intermediate chamber 159b" exceeds the cracking pressure of the second intake valve 165b", the second intake valve 165b" will open, and fluid in the first intermediate chamber 159a" will flow through the second set of intake orifices 158d" in the second intake valve body 155b", through the second intermediate chamber 159b", through the plurality of passages 204" in the cog ring 155d", through the central passage 158a" in the first intake valve assembly 154", and into the second working chamber 128". Also, the volume displaced by the piston rod 134" (i.e., rod volume) decreases during the extension / rebound stroke, so additional fluid flow must be supplied from the accumulator chamber 163 to compensate for the decrease in rod volume. Thus, some of the fluid in the accumulation chamber 163" flows through the accumulator port 144" and into the collector chamber 152", where it joins the extension flow path P2. The net flow of fluid out of the accumulation chamber 162" moves the floating piston 161" toward the intake valve assembly 154", thereby decreasing the size of the accumulation chamber 162". Thus, the intake valve assembly 154" allows fluid to flow bi-directionally into and out of the second working chamber 128".

[0124] Reference is made to Figure 17 and Figure 18, showing the cross-sectional shape of the collector chamber 152” and the relative alignment of the ports 140”, 142”, 144”, and 146” in the outer tube 136” of the damper 112”. The first control valve 164a” and the second control valve 164b” are externally mounted on the outer tube 136” such that the first control valve port 140” and the second control valve port 142” are circumferentially aligned with one another on the outer tube 136” along a control valve alignment axis AA. To minimize the overall height of the first control valve 164a” and the second control valve 164b”, a cover member 148” is externally mounted to the outer tube 136” such that the cover member abuts / contacts the outer cylindrical surface 131” of the outer tube 136” along the control valve alignment axis AA. As a result, the collector chamber 152” extends on each side of the control valve alignment axis AA. Due to this height-reducing arrangement, the accumulator port 144” in the outer tube 136” that leads into the accumulation chamber 162” and the open port 146” in the outer tube 136 that leads into the first intermediate chamber 159a” are each offset relative to the first control valve port 140” and the second control valve port 142” such that the accumulator port 144” and the open port 146” in the outer tube 136” are circumferentially spaced apart relative to the control valve alignment axis AA. In other words, the ports 140”, 142”, 144”, and 146” in the outer tube 136” of the damper 112” are arranged such that the control valve alignment axis AA bisects the first control valve port 140” and the second control valve port 142”, but does not bisect the accumulator port 144” and the open port 146” due to their offset arrangement, which results in the accumulator port 144” and the open port 146” being in direct fluid communication with the collector chamber 152”.

[0125] Further reference is made to Figures 19 to 21assembly 154" is shown. The first and second intake valve bodies 155a" and 155b" are configured as vented disks, while the bulkhead body 155c" is shaped like a solid disk. In this embodiment, there are no orifices or passages in the bulkhead body 155c". Thus, the bulkhead body 155c" acts as a fluid flow impediment such that there is no fluid flow through the bulkhead body 155c". The first intake valve body 155a" includes a first central bore 206a" extending therethrough. The first set of intake orifices 158b" are arranged circumferentially (i.e., radially outwardly) around the first central bore 206a". The second intake valve body 155b" includes a second central bore 206b" extending therethrough. The second set of intake orifices 158d" are arranged circumferentially (i.e., radially outwardly) around the second central bore 206b". The adapter ring 130" and the cog ring 155d" each have a cylindrical hub portion that directly abuts one of the first and second intake valve bodies 155a" and 155b", and a disk-shaped flange portion that retains the first and second intake valves 165a" and 165b", such that the adapter ring 130" and the cog ring 155d" both have a similar shape to the top hat. Additionally, the adapter ring 130" and the cog ring 155d" have third and fourth central bores 206c" and 206d", respectively. In the illustrated embodiment, the first central bore 206A" in the first intake valve body 155A", the second central bore 206b" in the second intake valve body 155b", the third central bore 206c" in the adapter ring 130", and the fourth central bore 206d" in the cog ring 155d" are aligned with each other and coaxially aligned with the central longitudinal axis A of the damper 112", and collectively define a central passage 158A" in the intake valve assembly 154". One advantage of this arrangement is that the adapter ring 130", the first and second intake valve bodies 155a" and 155b", and the cog ring 155d" do not need to be indexed or rotated to a particular orientation to align the central bores 206a-d", which is a problem in the embodiment shown in Figures 13 to 21 the first central bore 206A" in the first intake valve body 155A", the second central bore 206b" in the second intake valve body 155b", the third central bore 206c" in the adapter ring 130", and the fourth central bore 206d" in the cog ring 155d" are aligned with each other and coaxially aligned with the central longitudinal axis A of the damper 112", and collectively define a central passage 158A" in the intake valve assembly 154". One advantage of this arrangement is that the adapter ring 130", the first and second intake valve bodies 155a" and 155b", and the cog ring 155d" do not need to be indexed or rotated to a particular orientation to align the central bores 206a-d", which is a problem in the embodiment shown in Figures 8 to 12 the first central bore 206A" in the first intake valve body 155A", the second central bore 206b" in the second intake valve body 155b", the third central bore 206c" in the adapter ring 130", and the fourth central bore 206d" in the cog ring 155d" are aligned with each other and coaxially aligned with the central longitudinal axis A of the damper 112", and collectively define a central passage 158A" in the intake valve assembly 154". One advantage of this arrangement is that the adapter ring 130", the first and second intake valve bodies 155a" and 155b", and the cog ring 155d" do not need to be indexed or rotated to a particular orientation to align the central bores 206a-d", which is a problem in the embodiment shown in

[0126] It should be appreciated that the first intake valve 165a" controls fluid flow between the first intermediate chamber 159a" and the fluid transfer chamber 138" through the first set of intake orifices 158b". In the illustrated example, the first intake valve 165a" is a passive valve. More specifically, in the illustrated embodiment, the first intake valve 165a" includes a first spring disc stack 167a" held between the adapter ring 130" and the first intake valve body 155a". In operation, the first spring disc stack 167a" opens and closes the first intake orifices 158b" by flexing toward and away from the first intake valve body 155a" based on a pressure differential between the first intermediate chamber 159a" and the fluid transfer chamber 138". Thus, the first intake valve 165a" acts as a one-way valve that permits fluid flow in only one direction from the first intermediate chamber 159a" to the fluid transfer chamber 138". As noted above, this one-way flow through the first intake valve 165a" occurs during the compression stroke when the piston 124" is moving toward the intake valve assembly 154".

[0127] The second intake valve 165b" controls fluid flow between the first intermediate chamber 159a" and the second intermediate chamber 159b" through the second set of intake orifices 158d". In the illustrated example, the second intake valve 165b" is a passive valve. More specifically, in the illustrated embodiment, the second intake valve 165b" includes a second spring disc stack 167b" held between the second intake valve body 155b" and the tooth ring 155d". In operation, the second spring disc stack 167b" opens and closes the second intake orifices 158d" by flexing toward and away from the second intake valve body 155b" based on a pressure differential between the first intermediate chamber 159a" and the second intermediate chamber 159b". The second intake valve 165b" acts as a one-way valve that permits fluid flow in only one direction from the first intermediate chamber 159a" and the second intermediate chamber 159b". As noted above, this one-way flow through the second intake valve 165b" occurs during the extension stroke when the piston 124" is moving away from the intake valve assembly 154".

[0128] The tooth ring 155d" includes a plurality of teeth 208" arranged to abut the isolation wall body 155c". The plurality of teeth 208" are circumferentially spaced to define a plurality of passages 204" in the tooth ring 155d". The plurality of passages 204" in the tooth ring 155d" extend radially outward away from the central longitudinal axis A and thus permit fluid flow between the second intermediate chamber 159b" and the central passage 158a".

[0129] As Figure 22 and Figure 23As shown, the adapter ring 130", the first and second intake valve bodies 155a", 155b", and the tooth ring 155d" can be pre-assembled onto the retainer sleeve 210" prior to insertion into the outer tube 136" of the damper 112". As shown, Figure 22 As shown, the retainer sleeve 210" is press fit into the central bores 206a-d" of the adapter ring 130", the first and second intake valve bodies 155a", 155b", and the tooth ring 155d" such that the pre-load on the first and second spring disc stacks 167a", 167b" does not drive the components of the pre-assembly apart. Alternatively, the retainer sleeve 210" can be inserted into the central bores 206a-d" of the adapter ring 130", the first and second intake valve bodies 155a", 155b", and the tooth ring 155d" and then hammered or otherwise manipulated to create the outwardly flared mechanical deformation end 212" as shown prior to insertion of the pre-assembly into the outer tube 136" of the damper 112". Figure 23 As shown, the retainer sleeve 210" is press fit into the central bores 206a-d" of the adapter ring 130", the first and second intake valve bodies 155a", 155b", and the tooth ring 155d" such that the pre-load on the first and second spring disc stacks 167a", 167b" does not drive the components of the pre-assembly apart. Alternatively, the retainer sleeve 210" can be inserted into the central bores 206a-d" of the adapter ring 130", the first and second intake valve bodies 155a", 155b", and the tooth ring 155d" and then hammered or otherwise manipulated to create the outwardly flared mechanical deformation end 212" as shown prior to insertion of the pre-assembly into the outer tube 136" of the damper 112".

[0130] For example, an exemplary method of manufacturing damper 112 is set forth below. The method includes the steps of inserting accumulator insert 160” and then inserting intake valve assembly 154” into first outer tube end 137”. Intake valve assembly 154” is designed to be inserted in a sequentially ordered stack that includes, in order, tooth ring 155d”, second spring cup stack 167b”, second intake valve body 155b”, first intake valve body 155a”, first spring cup stack 167a”, and adapter ring 130”. In other words, tooth ring 155d” is the first component of intake valve assembly 154” to be inserted into first outer tube end 137”, and adapter ring 155d” is the last component of intake valve assembly 154” to be inserted into first outer tube end 137”. The method continues with the steps of inserting inner tube 122” into first outer tube end 137” and pressing second inner tube end 157” into contact with adapter ring 130” of intake valve assembly 154” such that intake valve assembly 154” is clamped between accumulator insert 160” and second inner tube end 157”. As noted above, the method can also include creating a pre-assembled intake valve assembly 154” prior to inserting intake valve assembly 154” into first outer tube end 137” by fitting tooth ring 155d”, second spring cup stack 167b”, second intake valve body 155b”, first intake valve body 155a”, first spring cup stack 167a”, and adapter ring 130” onto holder sleeve 210” to improve ease of assembly. Furthermore, all of these steps can be accomplished without any welding operations.

[0131] While aspects of the present disclosure have been particularly shown and described with reference to the embodiments discussed above, it will be understood by those of ordinary skill in the art that various additional embodiments can be contemplated by modifying the disclosed damper without departing from the spirit and scope of the disclosed content. Such embodiments should be understood to fall within the scope of the present disclosure as determined based on the claims and any equivalents thereof.

Claims

1. A damper, comprising: an inner tube extending longitudinally between a first inner tube end and a second inner tube end; a piston slidably disposed within the inner tube, the piston defining a first working chamber and a second working chamber; an outer tube disposed about the inner tube, the outer tube extending longitudinally between a first outer tube end and a second outer tube end, the first working chamber being arranged in fluid communication with a fluid transfer chamber disposed between the inner tube and the outer tube; a cover member mounted to the outer tube to define a collector chamber positioned exterior to the outer tube; and an intake valve assembly positioned within the outer tube to define an accumulation chamber arranged in fluid communication with the collector chamber, the intake valve assembly including a first intermediate chamber disposed in fluid communication with the collector chamber and the accumulation chamber and a second intermediate chamber disposed in fluid communication with the second working chamber; wherein the intake valve assembly includes a central passage extending longitudinally through the intake valve assembly and arranged in fluid communication with the second intermediate chamber and the second working chamber, wherein the intake valve assembly includes at least one intake valve controlling fluid flow through the intake valve assembly; wherein the intake valve assembly includes a first intake valve controlling fluid flow through the intake valve assembly between the first intermediate chamber and the fluid transfer chamber and a second intake valve controlling fluid flow through the intake valve assembly between the first intermediate chamber and the second intermediate chamber; wherein the intake valve assembly includes a first intake valve body adjacent the second inner tube end, an isolation wall body longitudinally spaced apart from the first intake valve body, and a second intake valve body longitudinally positioned between the first intake valve body and the isolation wall body, wherein the first intake valve is mounted to the first intake valve body and is configured to open and close a first intake orifice in the first intake valve body, wherein the second intake valve is mounted to the second intake valve body and is configured to open and close a second intake orifice in the second intake valve body, and wherein the first intake valve body and the second intake valve body and the isolation wall body abut an inner cylindrical surface of the outer tube; wherein the intake valve assembly includes an adapter ring longitudinally positioned in abutting arrangement between the second inner tube end and the first intake valve body and a tooth ring longitudinally positioned in abutting arrangement between the second intake valve body and the isolation wall body, the first intake valve is a spring disc stack longitudinally positioned between and held by the adapter ring and the first intake valve body, and the second intake valve is a spring disc stack longitudinally positioned between and held by the second intake valve body and the tooth ring. ​ 2. The damper of claim 1, wherein the first intermediate chamber is defined between the first intake valve body and the second intake valve body, and the second intermediate chamber is defined between the second intake valve body and the bulkhead body.

3. The damper of claim 2, wherein the first intake valve is a passive one-way valve that permits fluid flow through the first intake orifice in only one direction from the first intermediate chamber to the fluid transfer chamber, and the second intake valve is a passive one-way valve that permits fluid flow through the second intake orifice in only one direction from the first intermediate chamber to the second intermediate chamber.

4. The damper of claim 1, wherein the gear ring includes a plurality of teeth that abut the bulkhead body and are circumferentially spaced apart to define a plurality of radially extending passages in the gear ring that permit fluid flow between the second intermediate chamber and the central passage.

5. The damper of claim 4, wherein the first intake valve body and the second intake valve body, the adapter ring, and the gear ring include a central bore that is aligned with a central longitudinal axis of the damper and collectively form the central passage of the intake valve assembly.

6. The damper of claim 5, wherein the intake valve assembly includes a retainer sleeve that extends through the central bores of the first intake valve body and the second intake valve body, the adapter ring, and the gear ring to hold the intake valve assembly together as a subassembly before and after installation into the outer tube.

7. The damper of claim 1, wherein the first intake valve body includes a first passage that extends through the first intake valve body, and the second intake valve body includes a second passage that extends through the second intake valve body and is arranged in fluid communication with the first passage, such that the first passage and the second passage in the first intake valve body and the second intake valve body collectively form the central passage of the intake valve assembly.

8. The damper of claim 1, further comprising: an accumulator insert including an accumulator sleeve positioned inside the outer tube, a floating piston slidably disposed in the accumulator sleeve, and a pressurized chamber longitudinally positioned between the floating piston and the second outer tube end, the pressurized chamber containing a pressurized fluid that operates to bias the floating piston toward the intake valve assembly, wherein the accumulation chamber is defined between the intake valve assembly and the floating piston, wherein the accumulation chamber is arranged in fluid communication with the collector chamber via at least one accumulator port in the outer tube, wherein the bulkhead body is a fluid flow barrier that contains no orifices or passages such that there is no fluid flow through the bulkhead body, wherein the bulkhead body is positioned between the accumulator sleeve and the second intermediate chamber such that the intake valve assembly is clamped between the accumulator sleeve and the second inner tube end.

9. The damper of claim 1, further comprising: a first control valve externally mounted to the outer tube, the first control valve having a first control valve inlet arranged to be in fluid communication with the fluid delivery chamber via a first control valve port in the outer tube and a first control valve outlet arranged to be in fluid communication with the collector chamber; and a second control valve externally mounted to the outer tube, the second control valve having a second control valve inlet arranged to be in fluid communication with the second intermediate chamber via a second control valve port in the outer tube and a second control valve outlet arranged to be in fluid communication with the collector chamber, wherein the first control valve port and the second control valve port are circumferentially aligned with one another on the outer tube along a control valve alignment axis extending parallel to a central longitudinal axis of the damper.

10. The damper of claim 9, wherein the cover member abuts the outer tube along the control valve alignment axis such that the collector chamber extends on each side of the control valve alignment axis.

11. The damper of claim 9, wherein the one or more open ports in the outer tube are arranged to be aligned with the first intermediate chamber and the collector chamber to permit fluid flow between the first intermediate chamber and the collector chamber, the one or more open ports in the outer tube being offset relative to the first control valve port and the second control valve port such that the one or more open ports are circumferentially spaced apart relative to the control valve alignment axis.

12. The damper of claim 9, further comprising: an accumulator positioned inside the outer tube, a floating piston slidably disposed in the accumulator, and a pressurized chamber longitudinally positioned between the floating piston and the second outer tube end, the pressurized chamber containing a pressurized fluid operative to bias the floating piston toward the intake valve assembly such that an accumulation chamber is defined between the intake valve assembly and the floating piston, wherein the accumulation chamber is arranged to be in fluid communication with the collector chamber via one or more accumulator ports in the outer tube, wherein the one or more accumulator ports in the outer tube are offset relative to the first control valve port and the second control valve port such that the one or more accumulator ports are circumferentially spaced apart relative to the control valve alignment axis.

13. The damper of claim 1, wherein, the adapter ring is press fit onto the second inner tube end.

Images