Damper assembly

Abstract

A damper assembly includes a pressure tube defining a chamber. The damper assembly includes a body supported by the pressure tube. The body has a first surface and a second surface opposite the first surface and spaced apart from the first surface along an axis. The body defines a passage extending from the first surface to the second surface. The damper assembly includes an orifice disk movable from a non-deflected position to a first deflected position and movable from the first deflected position to a second deflected position. The orifice disk in the non-deflected position is spaced apart from the first surface radially outward and radially inward of the passage. The orifice disk in the first deflected position is spaced apart from the first surface radially outward of the passage and abuts the first surface radially inward of the passage. The orifice disk in the second deflected position abuts the first surface radially outward and radially inward of the passage.

Description

[0001] Cross-references to related applications

[0002] This patent application claims priority and all benefits to provisional patent applications filed on March 27, 2020, US 63 / 001,013, October 12, 2020, US 63 / 090,475, October 12, 2020, and US 63 / 090,510, the entire contents of which are incorporated herein by reference. Background Technology

[0003] Dampers are typically used in conjunction with a car's suspension system or other suspension systems to control the movement of a vehicle's wheels relative to the vehicle's body. To control movement, dampers are usually connected between the sprung (body) mass and the unsprung (suspension / drivetrain) mass of the vehicle.

[0004] A damper controls wheel movement by restricting the flow of fluid through its piston. As the damper moves toward a compression or extension position, fluid flows through the piston, for example, via a passage. This passage may have a fixed opening size. Movement resistance is provided by limiting the amount of fluid flowing through it. As the movement speed increases, the movement resistance may increase exponentially.

[0005] The disc can be used to control fluid flow through a channel, for example, by flexing or translating to increase or decrease the opening size at one end of the channel. Changing the opening size may alter the force response characteristics of the damper assembly. For example, increasing the opening size may decrease drag, while decreasing the opening size may increase drag. Summary of the Invention

[0006] A damper assembly provides variable and tunable resistance and can be configured to provide a desired responsive force that resists movement of the damper assembly depending on the speed and direction of movement (e.g., toward an extended or compressed position). For example, one or more orifice discs, check discs, or drain discs can adjust fluid flow through a channel, for example, by controlling the amount of surface area through which fluid can flow and the rate of change of such surface area.

[0007] The damper assembly includes a pressure tube defining a chamber. The damper assembly includes a body supported by the pressure tube. The body has a first surface and a second surface opposite the first surface and spaced apart from the first surface along an axis. The body defines a passage extending from the first surface to the second surface. The damper assembly includes an orifice disk movable from a non-deflected position to a first deflected position and movable from the first deflected position to a second deflected position. The orifice disk in the non-deflected position is spaced apart from the first surface radially outward and radially inward of the passage. The orifice disk in the first deflected position is spaced apart from the first surface radially outward of the passage and abuts the first surface radially inward of the passage. The orifice disk in the second deflected position abuts the first surface radially outward and radially inward of the passage.

[0008] The orifice disk can include an orifice at the passage.

[0009] The orifice disk can include an outer edge, and the orifice can extend radially inward from the outer edge.

[0010] The orifice can be in fluid communication with the passage when the orifice disk is in the second deflected position.

[0011] The damper assembly can include a check disk covering the orifice.

[0012] The orifice disk can be between the body and the check disk.

[0013] The damper assembly can include a fulcrum disk between the body and the orifice disk.

[0014] The fulcrum disk can be radially inward of the passage.

[0015] The first surface can include a first portion extending transverse to the axis and a second portion extending transverse to the axis and the first portion.

[0016] The first portion of the first surface can extend perpendicular to the axis.

[0017] The first portion of the first surface can be radially inward of the second portion of the first surface.

[0018] The second portion can extend away from the first portion and toward the second surface.

[0019] The passage can be at the second portion of the first surface.

[0020] The first surface radially inward of the passage can be spaced apart from the first surface radially outward of the passage along the axis.

[0021] The body can divide the chamber into a compression sub-chamber and a rebound sub-chamber, the first surface opposing the rebound sub-chamber.

[0022] The body can divide the chamber into a compression sub-chamber and a rebound sub-chamber, the first surface opposing the rebound sub-chamber.

[0023] The damper assembly can include a spring that urges the orifice disc toward the body.

[0024] The spring can include a body spaced apart from the orifice disc along the axis and an arm extending radially outward from the body along the axis and toward the orifice disc.

[0025] The orifice disc in the second deflected position can abut the first surface around the passage.

[0026] In the present disclosure and as described further herein, a body defining one or more passages is provided by the example pistons described herein. The piston defines one or more passages. Movement of the piston within a working chamber of a pressure tube causes fluid to flow between compression and rebound sub-chambers located on opposite sides of the piston. This fluid movement can cause a disc (e.g., a check disc, a drain disc, a spring disc, etc.) attached to the piston to deflect. Deflection of the disc attached to the piston controls the open size of the passages of the piston, regulates fluid flow therethrough, and provides a variable and tunable resistance to the damper assembly. Alternatively to the piston, the body can be a base attached to an end of the pressure tube of the damper assembly, the base defining one or more passages. The passages defined by the base can provide fluid flow between the working chamber of the pressure tube and a reservoir chamber outside of the pressure tube. The base can include surfaces, features, passages, etc. as described for the pistons herein. The various discs described herein can be attached to the base (e.g., as described for the discs attached to the pistons), including their orientation, relative position, etc. The base and the various discs can collectively provide a base valve (or compression valve) assembly that regulates fluid flow between the working chamber and the reservoir chamber. Movement of the piston within the working chamber of the pressure tube can cause fluid to flow between the working chamber and the reservoir chamber via the passages of the base and can cause the discs attached to the base to deflect. Deflection of the discs attached to the base controls the open size of the passages of the base, regulates fluid flow therethrough, and provides a variable and tunable resistance to the damper assembly. BRIEF DESCRIPTION OF DRAWINGS

[0027] Figure 1 is a perspective view of a vehicle having a plurality of damper assemblies.

[0028] Figure 2 is a perspective view of one of the damper assemblies.

[0029] Figure 3A This is an exploded view of the components of the damper assembly.

[0030] Figure 3B yes Figure 3A A continuation of the exploded view.

[0031] Figure 3C yes Figure 3B A continuation of the exploded view.

[0032] Figure 4 It is along Figure 3B A cross-sectional view of a portion of the damper assembly taken from line 4-4.

[0033] Figure 5 yes Figure 4 A cross-sectional view is shown, and the first fluid flow path is illustrated as the damper assembly moves toward the extended position.

[0034] Figure 6 This is a diagram of the force response curve of the damper assembly moving toward the extended position, and the diagram identifies the first part of the curve.

[0035] Figure 7 yes Figure 4 A cross-sectional view is shown, and the first fluid flow path is illustrated when the damper assembly moves toward the extended position and the fluid velocity and / or pressure difference is above a first threshold.

[0036] Figure 8 This is a diagram of the force response curve of the damper assembly moving toward the extended position, and the diagram identifies the second part of the curve.

[0037] Figure 9 yes Figure 4 A cross-sectional view is shown, and the first fluid flow path is illustrated when the damper assembly moves toward the extended position and the fluid velocity and / or pressure difference is above the second threshold.

[0038] Figure 10 This is a diagram of the force response curve of the damper assembly moving toward the extended position, and the diagram identifies the third part of the curve.

[0039] Figure 11 yes Figure 4 The cross-sectional view shows the first and second fluid flow paths when the damper assembly moves toward the extended position and the fluid velocity and / or pressure difference is above a third threshold.

[0040] Figure 12 This is a diagram of the force response curve of the damper assembly moving toward the extended position, and the diagram identifies the fourth part of the curve.

[0041] Figure 13 yes Figure 4a cross-sectional view and illustrates third and fourth fluid flow paths when the damper assembly is moving toward the compressed position and the fluid flow rate and / or pressure differential is above a second threshold.

[0042] Figure 14 a plot of a force response curve for the damper assembly moving toward the extended position and a force response curve for the damper assembly moving toward the compressed position. DETAILED DESCRIPTION

[0043] REFERENCE Figures 1 to 4 Where like numerals refer to like and corresponding parts throughout the several views, a vehicle 20 can include a plurality of damper assemblies 22. Each damper assembly 22 includes a pressure tube 24 defining a chamber 26. The damper assembly 22 includes a piston 28 slidable within the chamber 26 along an axis Al. The piston 28 includes a first surface 30. The piston 28 includes a second surface 32 opposite the first surface 30 and spaced from the first surface along the axis Al. The piston 28 defines a first passage 34 extending from the first surface 30 to the second surface 32. The damper assembly 22 includes orifice disks 36, 38 movable from an un-flexed position to a first flexed position and movable from the first flexed position to a second flexed position. As shown in FIG. 1, the orifice disks 36, 38 in the un-flexed position are spaced from the piston 28 radially outward and radially inward of the first passage 34, i.e., from a respective one of the first surface 30 or the second surface 32. The orifice disks 36, 38 in the first flexed position are spaced from the piston 28 radially outward of the first passage 34 and abut the piston 28 radially inward of the first passage 34, e.g., as shown in FIG. 2. The orifice disks 36, 38 in the second flexed position abut the first surface radially outward and radially inward of the first passage 34, as shown in FIG. 3. Figure 4 and Figure 5 As shown, the orifice disks 36, 38 in the un-flexed position are spaced from the piston 28 radially outward and radially inward of the first passage 34, i.e., from a respective one of the first surface 30 or the second surface 32. The orifice disks 36, 38 in the first flexed position are spaced from the piston 28 radially outward of the first passage 34 and abut the piston 28 radially inward of the first passage 34, e.g., as shown in FIG. 2. The orifice disks 36, 38 in the second flexed position abut the first surface radially outward and radially inward of the first passage 34, as shown in FIG. 3. Figure 7 As shown, the orifice disks 36, 38 in the un-flexed position are spaced from the piston 28 radially outward and radially inward of the first passage 34, i.e., from a respective one of the first surface 30 or the second surface 32. The orifice disks 36, 38 in the first flexed position are spaced from the piston 28 radially outward of the first passage 34 and abut the piston 28 radially inward of the first passage 34, e.g., as shown in FIG. 2. The orifice disks 36, 38 in the second flexed position abut the first surface radially outward and radially inward of the first passage 34, as shown in FIG. 3. Figure 9 and Figure 13 As shown, the orifice disks 36, 38 in the un-flexed position are spaced from the piston 28 radially outward and radially inward of the first passage 34, i.e., from a respective one of the first surface 30 or the second surface 32. The orifice disks 36, 38 in the first flexed position are spaced from the piston 28 radially outward of the first passage 34 and abut the piston 28 radially inward of the first passage 34, e.g., as shown in FIG. 2. The orifice disks 36, 38 in the second flexed position abut the first surface radially outward and radially inward of the first passage 34, as shown in FIG. 3.

[0044] Figure 1The illustrated vehicle 20 can be any type of passenger car or commercial vehicle, such as a car, truck, sport utility vehicle, crossover vehicle, van, minivan, taxi, bus, etc. The vehicle 20 includes a vehicle body 40 and a frame. The vehicle body 40 and frame can be of unitized construction. In unitized construction, the vehicle body 40 (e.g., a rocker panel) serves as the frame, and the vehicle body 40 (including the rocker panel, pillars, roof rails, etc.) is unitary, i.e., a continuous unitary unit. As another example, the vehicle body 40 and frame can have a body-on-frame construction (also referred to as a cab-on-frame construction). In other words, the vehicle body 40 and frame are separate components, i.e., modular, and the vehicle body 40 is supported on and attached to the frame. Alternatively, the vehicle body 40 and frame can have any suitable construction. The vehicle body 40 and / or frame can be formed of any suitable material, such as steel, aluminum, etc. The vehicle 20 includes wheels 42 that control movement (e.g., acceleration, deceleration, turning, etc.) of the vehicle 20 relative to the ground on which the vehicle 20 is supported. Vertical movement of the wheels 42 relative to the vehicle body 40 affects the amount of traction between the wheels 42 and the ground and the amount of vertical acceleration experienced by passengers of the vehicle 20, e.g., the ride feel experienced by the occupants, when the vehicle 20 is driven over rough roads, etc.

[0045] The damper assemblies 22 are typically used in conjunction with an automotive suspension system or other suspension system to control movement of the wheels 42 of the vehicle 20 relative to the vehicle body 40 of the vehicle 20. To control the movement, the dampers are typically connected between the sprung (vehicle body 40) and unsprung (suspension / driveline) masses of the vehicle 20.

[0046] Referring to Figure 2 The damper assemblies 22 can move from a compressed position to an extended position, and vice versa. The distance between the ends 44 of the damper assembly 22 in the compressed position is less than the distance between the ends of the damper assembly in the extended position. A spring or the like can urge the damper assembly 22 toward the extended position. Forces applied to the wheels 42 of the vehicle 20 (e.g., from bumps, potholes, etc.) can urge the damper assembly 22 toward the compressed position.

[0047] Each damper assembly 22 controls movement of the corresponding wheel 42 by restricting the flow of fluid into and out of, and / or between, working chambers of the damper, e.g., between the compression sub-chamber 46 and the rebound sub-chamber 48. For example, as the damper assembly 22 moves toward the compressed position or the extended position, fluid movement is caused by movement of the piston 28 within the pressure tube 24 of the damper assembly 22.

[0048] Damper assembly 22 defines an axis Al. Axis Al extends between end portions 44 of damper assembly 22. Damper assembly 22 is elongatable along axis Al. As used herein, the terms "axially," "radially," and "circumferentially" are relative to axis Al defined by damper assembly 22.

[0049] Pressure tube 24 defines a chamber 26. For example, pressure tube 24 can be hollow and tubular, enclosing chamber 26 therein. Chamber 26 is filled with a fluid (e.g., an incompressible hydraulic fluid). Movement of damper assembly 22 (e.g., to an extended position or a compressed position) can increase and / or decrease fluid pressure in pressure tube 24 (e.g., in compression sub-chamber 46 and rebound sub-chamber 48). Pressure tube 24 can be elongatable along axis Al of damper assembly 22. Pressure tube 24 can be metal or any suitable material.

[0050] Damper assembly 22 includes a rod 50 that extends away from and is movable relative to pressure tube 24. Rod 50 can be elongatable along axis Al of damper assembly 22. Rod 50 moves relative to pressure tube 24 when damper assembly 22 moves toward a compressed position or an extended position. Rod 50 can extend from within chamber 26 of pressure tube 24 to outside of chamber 26, e.g., from piston 28 and through rebound sub-chamber 48.

[0051] Piston 28 divides chamber 26 of pressure tube 24 into compression sub-chamber 46 and rebound sub-chamber 48, i.e., compression sub-chamber 46 on one side of piston 28 and rebound sub-chamber 48 on an opposite side of piston 28 along axis Al. An outer circumferential surface 66 of piston 28 can be sealed to an inner surface of pressure tube 24. Piston 28 is slidable within chamber 26 of pressure tube 24 along axis Al. Sliding of piston 28 along axis Al changes the volumes of compression sub-chamber 46 and rebound sub-chamber 48. For example, when damper assembly 22 moves toward a compressed position, the volume of compression sub-chamber 46 can decrease, and the volume of rebound sub-chamber 48 can increase. As another example, when damper assembly 22 moves toward a compressed position, the volume of rebound sub-chamber 48 can decrease, and the volume of compression sub-chamber 46 can increase. Piston 28 is connected to rod 50, i.e., such that piston 28 and rod 50 move in general unison. Piston 28 can be secured to rod 50, e.g., via fastener 52 and / or other suitable structure such as welding, friction fit, etc. Piston 28 can be metal, plastic, or any suitable material.

[0052] With reference to Figures 3A to 4The first surface 30 and the second surface 32 of the piston 28 extend from radially outward of the stem 50 to an outer circumferential surface 66 of the piston 28. The first surface 30 can be opposite the second surface 32 and spaced along the axis Al from the second surface 32. The second surface 32 can be opposite the compression sub-chamber 46 relative to the piston 28 and along the axis Al. The first surface 30 is opposite the rebound sub-chamber 48 relative to the piston 28 and along the axis Al. For example, the first surface 30 can face the rebound sub-chamber 48, and the second surface 32 is between the first surface 30 and the rebound sub-chamber 48. As another example, the second surface 32 can face the compression sub-chamber 46, and the first surface 30 is between the second surface 32 and the compression sub-chamber 46.

[0053] The first surface 30 and / or the second surface 32 can each include a first portion 54, 56 extending transversely relative to the axis Al. For example, the first portion 54, 56 of the respective first surface 30 or second surface 32 can extend away from the stem 50 and perpendicularly relative to the axis Al. The axis Al can extend orthogonally relative to the first portion 54, 56 of the first surface 30 and / or the second surface 32.

[0054] The first surface 30 and / or the second surface 32 can each include a second portion 58, 60. The second portion 58, 60 extends transversely relative to the axis Al and the respective first portion 54, 56. The slope of the first portion 54, 56 is different than the slope of the second portion 58, 60 relative to the axis Al. For example, the second portion 58 of the first surface 30 can extend transversely relative to the first portion 54 of the first surface 30, and the second portion 60 of the second surface 32 can extend transversely relative to the first portion 56 of the second surface 32. The second portion 58, 60 extends away from the respective first portion 54, 56 and toward the first surface 30 or the second surface 32 opposite the respective second portion 58, 60. For example, the second portion 58 of the first surface 30 can extend relative to the axis Al from the first portion 54 toward the second surface 32. The second portion 60 of the second surface 32 can extend relative to the axis Al from the first portion 56 toward the first surface 30. The second portion 58, 60 is shown as a linear cross-section extending from the first portion 54, 64. Alternatively, the second portion 58, 60 can include a radius, for example, the second portion 58, 60 of the first surface 30 or the second surface 32 can curve toward the opposite direction of the respective second portion 58, 60. The first portion 54, 56 is radially inward of the respective second portion 58, 60. For example, the first portion 54 of the first surface 30 can be radially between the stem 50 and the second portion 58 of the first surface 30. The first portion 56 of the second surface 32 can be radially between the stem 50 and the second portion 60 of the second surface 32. The distance between the first surface 30 and the second surface 32 along the axis Al can be less at the second portion 58, 60 than at the first portion 54, 56.

[0055] The bends 62, 64 can be defined between the first portions 54, 56 and the second portions 58, 60 of the first surface 30 and / or the second surface 32. The bends 62, 64 are defined by a difference in slope of the first portions 54, 56 and the second portions 58, 60. For example, the bend 62 of the first surface 30 can be defined by a difference in slope of the first portion 54 and the second portion 58 of the first surface 30. As another example, the bend 64 of the second surface 32 can be defined by a difference in slope of the first portion 56 and the second portion 60 of the second surface 32. The bends 62, 64 are radially between the first portions 54, 56 and the second portions 58, 60 of the respective first surface 30 and / or second surface 32. The distance between the second portion 58 of the first surface 30 and the second portion 60 of the second surface 32 along the axis Al is greater at the bends 62, 64 than at the outer circumferential surface 66 of the piston 28. The bends 62, 64 are shown as having substantially the same difference in slope. Alternatively, the bends 62, 64 can be defined by different slopes. For example, the slope of the bend 62 on one side of the first surface 30 can be different than the slope of the bend 62 that is circumferentially opposite (e.g., 180 degrees apart around the axis Al) from the bend 62.

[0056] The piston 28 defines one or more channels, such as one or more first channels 34, second channels 68, and third channels 70. The channels 34, 68, 70 extend from the first surface 30 of the piston 28 to the second surface 32 of the piston 28. The channels 34, 68, 70 can be circumferentially spaced apart around the axis Al. The channels 34, 68, 70 provide fluid communication between the compression sub-chamber 46 and the rebound sub-chamber 48 of the pressure tube 24, i.e., such that fluid can flow from the compression sub-chamber 46 to the rebound sub-chamber 48 in a first direction Dl, or from the rebound sub-chamber to the compression sub-chamber in a second direction D2 that is opposite the first direction Dl. The first direction Dl is shown in the figures as from the second surface 32 to the first surface 30, however the first direction Dl can be from the first surface 30 to the second surface 32.

[0057] The first passage 34 can be located at the second portion 58 of the first surface 30 and / or the second portion 60 of the second surface 32. For example, the first passage 34 can extend from an open end at the second portion 58 of the first surface 30 to an open end at the second portion 60 of the second surface 32. The open ends can be surrounded by the respective second portions 58, 60. The first surface 30 radially inward of the first passage 34 can be spaced apart from the first surface 30 radially outward of the first passage 34 along the axis Al. The second surface 32 radially inward of the first passage 34 can be spaced apart from the second surface 32 radially outward of the first passage 34 along the axis Al. For example, the distance between the first surface 30 and the second surface 32 along the axis Al radially inward of the first passage 34 can be greater than the distance between the first surface 30 and the second surface 32 along the axis Al radially outward of the first passage 34. The bends 62, 64 can be radially inward of the first passage 34, for example, the bends 62, 64 can be located between the first passage 34 and the stem 50 perpendicular to the axis Al. The bends 62, 64 can also be located at the radially outward of the first passage 34 (not shown).

[0058] The damper assembly 22 can include one or more fulcrum disks 72, 74, for example, one fulcrum disk 72 at the first surface 30 and / or one fulcrum disk 74 at the second surface 32. The fulcrum disks 72, 74 provide a fulcrum for the orifice disks 36, 38 and the check disks 76, 78. For example, one of the fulcrum disks 72 can abut the first surface 30. Another of the fulcrum disks 74 can abut the second surface 32. The fulcrum disks 72, 74 can extend from radially outward of the stem 50 to outer edges 80, 82. The fulcrum disks 72, 74 can be radially inward of the passages 34, 68, 70. For example, the outer edges 80, 82 of the fulcrum disks 72, 74 can be radially inward of the bends 62, 64.

[0059] The damper assembly 22 can include one or more check disks 76, 78, for example, a check disk 76 at the first surface 30 and a check disk 78 at the second surface 32. The check disks 76, 78 increase the resistance to movement in response to fluid flow through the respective check disk 76, 78 and / or a difference in fluid pressure on one side of the check disk 76, 78 relative to the opposite side. The fluid flow and / or the difference in fluid pressure can cause the check disk 76, 78 to translate or flex to decrease the size of an opening 84, 86 (shown in Figure 4 , Figure 5 , Figure 7 , Figure 9 and Figure 11 ) through which fluid can flow, thereby increasing the resistance to movement. The check disks 76, 78 can be supported by the piston 28 and / or the stem 50, for example, via a central opening of each of the check disks 76, 78.

[0060] The check disks 76, 78 can extend fromFigure 4 and Figure 5 to a first flexed position shown in FIG. 6B (illustrating check discs 76 in the first flexed position). When moving from the non-flexed position to the first flexed position, check discs 76, 78 can flex at respective fulcrum discs 72, 74. Respective openings 84, 86 can be smaller in the first flexed position than in the non-flexed position. Check discs 76, 78 can also move from the first flexed position to a second flexed position shown in FIG. 6C. When moving from the first flexed position to the second flexed position, check discs 76, 78 can flex at respective bends 62, 64. Respective openings 84, 86 can be smaller in the second flexed position than in the first flexed position. Figure 7 Figure 9 and Figure 11 to a first flexed position shown in FIG. 6B (illustrating check discs 76 in the first flexed position). When moving from the non-flexed position to the first flexed position, check discs 76, 78 can flex at respective fulcrum discs 72, 74. Respective openings 84, 86 can be smaller in the first flexed position than in the non-flexed position. Check discs 76, 78 can also move from the first flexed position to a second flexed position shown in FIG. 6C. When moving from the first flexed position to the second flexed position, check discs 76, 78 can flex at respective bends 62, 64. Respective openings 84, 86 can be smaller in the second flexed position than in the first flexed position.

[0061] to a first flexed position shown in FIG. 6B (illustrating check discs 76 in the first flexed position). When moving from the non-flexed position to the first flexed position, check discs 76, 78 can flex at respective fulcrum discs 72, 74. Respective openings 84, 86 can be smaller in the first flexed position than in the non-flexed position. Check discs 76, 78 can also move from the first flexed position to a second flexed position shown in FIG. 6C. When moving from the first flexed position to the second flexed position, check discs 76, 78 can flex at respective bends 62, 64. Respective openings 84, 86 can be smaller in the second flexed position than in the first flexed position. Figures 3A to 4 , check discs 76, 78 can include extensions 88, 90 extending radially outward from base rings 92, 94 of respective check discs 76, 78. Extensions 88, 90 can oppose one another, e.g., be approximately 180 degrees apart from one another about axis Al. Check discs 76, 78 can be bowtie-shaped. For example, extensions 88, 90 can increase in width along extensions 88, 90, e.g., such that extensions 88, 90 widen as extensions 88, 90 extend away from respective base rings 92, 94. Although shown as each having two extensions 88, 90, check discs 76, 78 can each include only one or more than two extensions 88, 90. Extensions 88, 90 can cover first passageway 34. For example, extensions 96, 98 can be circumferentially aligned with and radially extend beyond first passageway 34.

[0062] The amount of flexing and / or translation of check discs 76, 78 (and the associated reduction in opening size) can be proportional to the fluid flow rate and / or pressure differential between compression subchamber 46 and rebound subchamber 48 of chamber 26. For example, the greater the fluid flow rate and / or fluid pressure differential, the greater the amount of flexing and / or translation of check discs 76, 78. The proportionality of the amount of flexing and / or translation of check discs 76, 78 to the fluid flow rate and / or pressure differential can vary depending on whether check discs 76, 78 are moving between the non-flexed position and the first flexed position or between the first flexed position and the second flexed position. For example, the fluid flow required to move from the non-flexed position to the first flexed position is typically less than the fluid flow required to move from the first flexed position to the second flexed position.

[0063] ​A threshold fluid flow rate and / or fluid pressure differential can be required to flex and / or translate the check disks 76, 78. The check disks 76, 78 can not increase the resistance to movement until the threshold fluid flow rate and / or fluid pressure differential is reached. The threshold fluid flow rate and / or fluid pressure differential can be determined based on the desired response characteristics of the damper assembly 22, which can be designed, for example, via geometry such as thickness, material type, etc., to flex at the threshold fluid flow rate and / or fluid pressure differential. For example, increasing the thickness of the check disks 76, 78 and / or selecting a stiffer material for the check disks 76, 78 can increase the threshold fluid flow rate and / or fluid pressure differential required to reduce the size of the openings 84, 86. Reducing the thickness of the check disks 76, 78 and / or selecting a more flexible material for the check disks 76, 78 can reduce the threshold fluid flow rate and / or fluid pressure differential required to reduce the size of the openings 84, 86.

[0064] The check disk 76 at the first surface 30 selectively restricts fluid flow through the first passage 34 in the second direction D2, i.e., depending on the direction and amount of fluid pressure applied to the check disk 76 and / or the speed of fluid flow. The check disk 78 at the first surface 30 selectively allows fluid flow through the first passage 34 by controlling the size of the opening 84 between the check disk 76 and the first surface 30 of the piston 28. The check disk 78 at the second surface 32 selectively restricts fluid flow through the first passage 34 in the first direction Di by controlling the size of the opening 86 between the check disk 78 and the second surface 32 of the piston 28.

[0065] As the damper assembly 22 moves toward the extended position, the volume of the compression sub-chamber 46 increases and the volume of the rebound sub-chamber 48 decreases, thereby creating a pressure differential in which the fluid pressure in the rebound sub-chamber 48 is greater than the fluid pressure in the compression sub-chamber 46. This pressure differential and / or fluid flow resulting from this pressure differential can cause the check disk 76 at the first surface 30 to move toward the piston 28, thereby reducing the size of the opening 84 through which fluid can flow and increasing the resistance to movement provided by the damper assembly 22.

[0066] As the damper assembly 22 moves toward the extended position, the volume of the compression sub-chamber 46 increases and the volume of the rebound sub-chamber 48 decreases, thereby creating a pressure differential in which the fluid pressure in the rebound sub-chamber 48 is greater than the fluid pressure in the compression sub-chamber 46. This pressure differential and / or fluid flow resulting from this pressure differential can cause the check disk 76 at the first surface 30 to move toward the piston 28, thereby reducing the size of the opening 84 through which fluid can flow and increasing the resistance to movement provided by the damper assembly 22.

[0067] The damper assembly 22 may include one or more orifice discs 36, 38, for example, one orifice disc 36 at a first surface 30 and / or one orifice disc 36, 38 at a second surface 32. The orifice discs 36, 38 may be supported by a rod 50 and / or a piston 28, for example, via a central opening of the respective orifice disc 36, 38. The orifice discs 36, 38 may be located, for example, along axis A1 between the piston 28 and the corresponding check discs 76, 78. One side of the orifice discs 36, 38 may be adjacent to a corresponding pivot disc 72, 74, for example, opposite the piston 28 relative to axis A1. The pivot discs 72, 74 may be located along axis A1 between the piston 28 and the corresponding orifice discs 36, 38.

[0068] The orifice plates 36 and 38 may include extensions 96 and 98 extending radially outward from the base rings 100 and 102 of the respective orifice plates 36 and 38. The extensions 96 and 98 may be opposite each other, for example, spaced approximately 180 degrees apart about axis A1. The outer edges of the base rings 100 and 102 may be aligned with the outer edges 80 and 82 of the respective pivot plates 72 and 74. For example, the outer edges of the base rings 100 and 102 and the outer edges 80 and 82 of the respective pivot plates 72 and 74 may be spaced approximately equidistant from axis A1. The orifice plates 36 and 38 may be bow-shaped. For example, the width of the extensions 96 and 98 may increase along the extensions 96 and 98, for example, such that the extensions 96 and 98 widen as they extend away from the base rings 100 and 102. The extensions 96 and 98 of the orifice discs 36 and 38 may, for example, be circumferentially aligned with the extensions 88 and 90 of the check discs 76 and 78 relative to axis A1. Although shown as having two extensions 96 and 98 respectively, the orifice discs 36 and 38 may each include only one or more extensions 96 and 98. The extensions 96 and 98 may cover the first channel 34. For example, the extensions 96 and 98 may be circumferentially aligned with the first channel 34 and extend radially beyond the first channel.

[0069] Each orifice disc 36, 38 defines one or more orifices 104, 106. The orifices 104, 106 allow fluid to flow axially and / or radially relative to the axis Al of the damper assembly 22. Each orifice 104, 106 can be open in a radial direction. For example, the orifices 104, 106 can extend radially inward from an outer edge of the extension 96, 98 of the respective orifice disc 36, 38, e.g., such that fluid can flow radially into the orifices 104, 106 at the outer edge. The orifices 104, 106 of the orifice discs 36, 38 can be generally circumferentially aligned at the first passage 34, e.g., relative to the open end of the first passage 34, and spaced generally radially equidistant from the open end of the first passage. The check discs 76, 78 can cover the orifices 104, 106. For example, the extensions of the check discs 76, 78 can extend circumferentially and radially across the orifices 104, 106. When the check discs 76, 78 are in the second flexed position, the orifices 104, 106 enable fluid to flow through the first passage 34 by maintaining a minimum size of the openings 84, 86 between the check discs 76, 78 and the piston 28. For example, the minimum size of the openings can be equal to the radial flow area of the orifices 104, 106.

[0070] The orifice discs 36, 38 can move from the unflexed position to the first flexed position, and can move from the first flexed position to the second flexed position, e.g., in response to fluid flow through the respective orifice disc 36, 38, as described for the check discs 76, 78. The orifice discs 36, 38 can move simultaneously with the check discs 76, 78. For example, movement of the check disc 78 at the second surface 32 from the unflexed position to the first flexed position can urge the orifice disc 38 at the second surface 32 from the unflexed position to the first flexed position. As another example, movement of the check disc 76 at the first surface 30 from the first flexed position to the second flexed position can urge the orifice disc 36 at the first surface 30 from the first flexed position to the second flexed position.

[0071] The orifice discs 36, 38 in the unflexed position are spaced apart from the respective first surface 30 or second surface 32 radially outward and radially inward of the first passage 34. For example, the extension 96 of the orifice disc 36 at the first surface 30 in the unflexed position can be spaced apart from the curved portion 62 and the second portion 58 of the first surface 30. The extension 98 of the orifice disc 38 at the second surface 32 in the unflexed position can be spaced apart from the curved portion 64 and the second portion 60 of the second surface 32. The orifice discs 36, 38 in the unflexed position can be planar and extend generally perpendicular relative to the axis Al.

[0072] Orifice plates 36, 38 in the first flexed position are spaced apart from a corresponding first surface 30 or second surface 32 radially outward of the first channel 34, and abut against a corresponding first surface 30 or second surface 32 radially inward of the first channel 34. For example, an extension 96 of orifice plate 36 at the first surface 30 in the first flexed position may abut against the bend 62 and be spaced apart from the second portion 58 of the first surface 30. An extension 98 of orifice plate 38 at the second surface 32 in the first flexed position may abut against the bend 64 and be spaced apart from the second portion 60 of the second surface 32. Orifice plates 36, 38 in the first flexed position may include, for example, fulcrum plates 72, 74 ( Figure 7 , Figure 9 , Figure 11 and Figure 13 The first bends 108 and 110 are shown.

[0073] Orifice discs 36, 38 in the second flexed position are adjacent to corresponding first surfaces 30 or second surfaces 32 on the radially outer and radially inner sides of the first channel 34. For example, an extension 96 of orifice disc 36 on the first surface 30 in the first flexed position may be adjacent to the bend 62 and the second portion 58 on the outer side of the first channel 31 on the first surface 30. An extension 98 of orifice disc 38 on the second surface 32 in the second position may be adjacent to the bend 64 and spaced apart from the second portion 60 on the outer side of the first channel 34 on the second surface 32. Orifice discs 36, 38 in the second flexed position may include, for example, second bends 112, 114 at the bends 62, 64 on the corresponding first surfaces 30 or second surfaces 32. Orifice discs 36, 38 in the second flexed position are adjacent to corresponding first surfaces 30 or second surfaces 32 surrounding the first channel 34, wherein orifices 104, 106 are in fluid communication with the first channel 34. The adjacency of the first surface 30 or the second surface 32 surrounding the first channel 34 with the orifices 104, 106 that are in fluid communication with the first channel 34 inhibits the flow of fluid into the first channel 34 except through the orifices 104, 106.

[0074] The damper assembly 22 may include one or more springs 116, 118, such as spring 116 at a first surface 30 and spring 118 at a second surface 32. Springs 116, 118 push check discs 76, 78, fulcrum discs 36, 38, and fulcrum discs 72, 74 toward piston 28. For example, spring 116 at the first surface 30 may compress check disc 76, orifice disc 36, and fulcrum disc 72 against the first surface 30. As another example, spring 118 at the second surface 32 may compress check disc 78, orifice disc 38, and fulcrum disc 74 against the second surface 32.

[0075] Each of the springs 116, 118 can include a body 120, 122 spaced apart from the orifice disks 36, 38 along the axis Al. Each of the springs 116, 118 can include a plurality of arms 124, 126 extending circumferentially and radially outward from the body 120, 122 and along the axis Al toward the respective orifice disk 36, 38. The springs 116, 118 can be supported by the stem 50, e.g., via a central opening of the body 120, 122. The springs 116, 118 are made of an elastically deformable material having suitable elastic properties (e.g., spring steel, plastic). The arms 124, 126 of the springs 116, 118 can abut the check disks 76, 78. For example, the arms 124 of the spring 116 at the first surface 30 can abut the check disk 76 at the first surface 30 opposite the orifice disk 36 relative to the axis Al. As another example, the arms 126 of the spring 118 at the second surface 32 can abut the check disk 78 at the second surface 32 surface opposite the orifice disk 38 relative to the axis Al.

[0076] The damper assembly 22 can include one or more drain disks 128, 130, e.g., a drain disk 128 at the first surface 30 and / or a drain disk 130 at the second surface 32. The drain disks 128, 130 can be supported by the stem 50. For example, each of the drain disks 128, 130 can include a central opening, and the stem 50 can be located in the central opening. The drain disks 128, 130 can be located axially outward of the springs 116, 118 relative to the piston 28. For example, the drain disk 128 at the first surface 30 can abut the spring 116 opposite the first surface 30. As another example, the drain disk 130 at the second surface 32 can abut the spring 118 opposite the second surface 32.

[0077] The drain disks 128, 130 reduce the resistance to movement in response to fluid flow through the drain disks 128, 130 and / or a difference in fluid pressure on one side of the drain disks 128, 130 relative to the opposite side. The fluid flow and / or the difference in fluid pressure can cause the drain disks 128, 130 to translate or flex to form openings 132, 134 through which fluid can flow (in the direction of the fluid flow and / or the pressure difference). The openings 132, 134 can be formed in the drain disks 128, 130 by the arms 124, 126 of the springs 116, 118. Figure 11 and Figure 13The size of the openings 132, 134 is increased by allowing a greater amount of fluid to flow from one sub-chamber 46, 48 to the other sub-chamber 46, 48, thereby reducing the resistance to movement. The amount of flexure and / or translation of the drain disc 128, 130 and the resulting increase in the size of the openings 132, 134 can be proportional to the fluid flow rate and / or pressure differential between the compression sub-chamber 46 and the rebound sub-chamber 48. For example, the greater the fluid flow rate and / or fluid pressure differential, the greater the amount of flexure and / or translation of the drain disc 128, 130 away from the piston 28, thereby providing a greater magnitude of increase in the size of the openings 132, 134 therebetween. A threshold fluid flow rate and / or fluid pressure differential can be required to cause the drain disc 128, 130 to flex and / or translate. The drain disc 128, 130 can not reduce the resistance to movement until the threshold fluid flow rate and / or fluid pressure differential is reached.

[0078] Each drain disc 128, 130 can define one or more openings 136, 138. The openings 136, 138 allow fluid to flow from one side of the respective drain disc 128, 130 to the other side of the respective drain disc 128, 130. The openings 136, 138 can reduce the stiffness of the drain disc 128, 130. The openings 136, 138 can be arranged about the axis Al. The openings 136, 138 of each drain disc 128, 130 can overlap circumferentially, i.e., two or more openings 136, 138 can be along a common radius extending from the axis Al. Such openings 136, 138 can be spaced apart from each other along the radius.

[0079] The drain disc 128 at the first surface 30 can be spaced apart from the first surface 30 at the second passage 68. Spacing the drain disc 128 apart from the first surface 30 at the second passage 68 allows fluid to flow freely into and out of the second passage 68, e.g., without being inhibited from such flow by the drain disc 128 at the first surface 30.

[0080] The drain disc 128 at the first surface 30 selectively allows fluid to flow out of the third passage 70, i.e., depending on the amount and direction of fluid pressure applied to the drain disc 128. For example, the drain disc 128 at the first surface 30 can selectively allow fluid to flow through the third passage 70 in the second direction D2. The drain disc 128 selectively allows fluid flow by controlling the size of the openings 132 between the drain disc 128 and the first surface 30 of the piston 28 at the third passage 70.

[0081] When the damper assembly 22 is in a neutral state, i.e., not moving toward the extended position or the compressed position, the drain disc 128 at the first surface 30 covers the third passage 70 and restricts or inhibits fluid flow into and / or out of the third passage 70. The drain disc 128 in the neutral state can abut the first surface 30 of the piston 28 at the third passage 70, e.g., around the open end of the second passage 68.

[0082] When the damper assembly 22 moves toward the compressed position, the drain disc 128 at the first surface 30 can be moved away from the piston 28 by the pressure differential and / or fluid flow created by such movement. Moving the drain disc 128 away from the piston 28 creates an opening 132 between the first surface 30 of the piston 28 and the drain disc 128. Fluid can flow out of the third passage 70 through the opening 132 to the rebounder chamber 48.

[0083] When the damper assembly 22 moves toward the extended position, the drain disc 128 at the first surface 30 can be pushed toward the piston 28 without creating or enlarging the opening 132 between the first surface 30 of the piston 28 and the drain disc 128.

[0084] The drain disc 130 at the second surface 32 can be spaced apart from the second surface 32 at the third passage 70. Spacing the drain disc 130 apart from the second surface 32 at the third passage 70 allows fluid to freely flow into and out of the second passage 68, e.g., without being inhibited from such flow by the drain disc 130 at the second surface 32.

[0085] The drain disc 130 at the second surface 32 selectively allows fluid to flow out of the second passage 68 of the piston 28, i.e., depending on the amount and direction of fluid pressure applied to the drain disc 130. For example, the drain disc 130 at the second surface 32 can selectively allow fluid to flow through the second passage 68 in a first direction Dl. The drain disc 130 selectively allows fluid flow by controlling the size of an opening 134 between the drain disc 130 and the second surface 32 of the piston 28.

[0086] When the damper assembly 22 is in a neutral state, the drain disc 130 at the second surface 32 covers the second passage 68 at the second surface 32 and restricts or inhibits fluid flow into and out of the second passage 68. The drain disc 130 in the neutral state can abut the second surface 32 of the piston 28 at the second passage 68, e.g., around the open end of the second passage 68.

[0087] When the damper assembly 22 moves toward the extended position and the pressure in the rebounder chamber 48 is greater than the pressure in the compressor chamber 46, the drain disc 130 at the second surface 32 can move away from the piston 28 and create an opening 134 between the second surface 32 and the drain disc 130. Fluid can flow out of the second passage 68 through the opening 134 to the compressor chamber 46.

[0088] When the damper assembly 22 is moved toward the compressed position and the fluid pressure in the compression sub-chamber 46 is greater than the fluid pressure in the rebound sub-chamber 48, the discharge disc 130 at the second surface 32 can be pushed toward the piston 28 without creating an opening 134 between the piston 28 and the discharge disc 130 or enlarging the opening.

[0089] The damper assembly 22 can include one or more spring discs 140a-140d, 142a- 142d, such as one or more spring discs 140a-140d at the first surface 30 and / or one or more spring discs 142a-142d at the second surface 32. The spring discs 140a-140d, 142a- 142d can be supported by the rod 50. For example, the rod 50 can extend through central openings of the spring discs 140a-140d, 142a-142d. The spring discs 140a-140d, 142a- 142d can be elastically deformable. For example, a force applied to an outer edge of a spring disc 140a-140d, 142a-142d can cause the spring disc 140a-140d, 142a-142d to flex such that the outer edge moves axially relative to a respective central opening of the spring disc 140a-140d, 142a-142d. The spring discs 140a-140d, 142a-142d are made of an elastically deformable material having suitable elastic properties (e.g., spring steel, plastic, etc.).

[0090] The spring discs 140a-140d at the first surface 30 push the discharge disc 128 at the first surface 30 toward the piston 28, i.e., the spring discs 140a-140d increase the amount of force required to flex the discharge disc 128 away from the first surface 30. The spring discs 142a-142d at the second surface 32 push the discharge disc 130 at the second surface 32 toward the piston 28, i.e., the spring discs 142a-142d increase the amount of force required to flex the discharge disc 130 away from the second surface 32.

[0091] The spring discs 140a-140d, 142a-142d can gradually decrease in size with distance from the piston 28 along the axis Al. For example, an outer diameter of a spring disc 140a, 142a closest to the piston 28 can be greater than an outer diameter of a spring disc 140b, 142b adjacent to the spring disc 140a, 142a, and so on. A diameter of a spring disc 140d, 142d farthest from the piston 28 can be smaller than diameters of the other spring discs 140a-140c, 142a-142c. As another example, the spring discs 140a-140d, 142a-142d can be configured similar to a leaf spring.

[0092] The spring cups 140d, 142d closest to the piston 28 can abut the respective dump cups 128, 130 of the rod 50. The spring cups 140a, 142a closest to the piston 28 can be spaced apart from the dump cups 128, 130 at the outer edges of the dump cups 128, 130. For example, the ring 144 at the first surface 30 can be between the spring cup 140a at the first surface 30 and the dump cup 128 along the axis Al. As another example, the ring 146 at the second surface 32 can be between the spring cup 142a at the second surface 32 and the dump cup 130 along the axis Al. The rings 144, 146 can be circular or any suitable shape. The rings 144, 146 can be metal, plastic, or any suitable material. The rings 144, 146 provide an internal pre-tension to the spring cups 140a-140d, 142a-142d. The rings 144, 146 can be radially outward of the openings 136, 138 of the dump cups 128, 130.

[0093] Each damper assembly 22 can include a pair of second fulcrum cups 148, 150. The second fulcrum cups 148, 150 provide a fulcrum for the spring cups 140a-140d, 142a-142d. For example, one of the second fulcrum cups 148 can abut the smallest spring cup 140d at the first surface 30 opposite the adjacent larger spring cup 140c. Such a second fulcrum cup 148 can have a smaller outer diameter than the abutting smallest spring cup 140d. As another example, the second fulcrum cup 150 at the second surface 32 can abut the smallest spring cup 142d at the second surface 32 opposite the adjacent larger spring cup 142c. Such a second fulcrum cup 150 can have a smaller outer diameter than the smallest spring cup 142d at the second surface 32.

[0094] Each damper assembly 22 can include a pair of pre-tension washers 152, 154. The pre-tension washers 152, 154 protect the spring cups 140a-140d, 142a-142d. The pre-tension washers 152, 154 sandwich the piston 28, the cups, and other components of the damper assembly 22 supported by the rod 50. The thickness of the pre-tension washers 152, 154 can increase or decrease the space available for the cups, the piston 28, etc. For example, the pre-tension washer 152 at the first surface 30 can be axially outward of the second fulcrum cup 148 at the first surface 30, and the pre-tension washer 154 at the second surface 32 can be axially outward of the second fulcrum cup 150 at the second surface 32. The fastener 52 can be secured to the rod 50 axially outward of the pre-tension washer 152 at the second surface 32. The fastener 52 can be, for example, a threaded lock nut. The fastener 52 can constrain the pre-tension washers 152, 154, the dump cups 128, 130, the spring cups 140a-140d, 142a-142d, the piston 28, etc. to a predetermined length stack.

[0095] ReferringFigure 5 The first fluid flow path FF1 is defined by the damper assembly 22 is shown. The first fluid flow path FF1 is defined when the damper assembly 22 is moved toward the extended position. The first fluid flow path extends from the rebound sub-chamber 48 around the pre-tension washer 152, the spring cups 140a-140d, and the drain cup 128 to the opening 84 between the check cup 76 and the first surface 30 of the piston 28. The first fluid flow path FF1 extends from the opening 84 through the first passage 34 and from the opening 86 between the check cup 78 and the second surface 32 to the compression sub-chamber 46.

[0096] The first fluid flow path FF1 defines an area, for example perpendicular to the first fluid flow path FF1, through which fluid can flow. The defined area can be at a narrowest portion of the respective first fluid flow path FF1. The defined area can include multiple areas. For example, the first fluid flow path FF1 can be divided into multiple sub-paths, for example, each extending through one of the first passages 34. The sub-paths can each have a sub-area at a narrowest portion of the respective sub-path, and the defined area of the first fluid flow path FF1 can be a combination of the areas of the sub-paths.

[0097] The defined area of the first fluid flow path FF1 provides resistance to movement of the piston 28 by limiting the rate at which fluid can flow from the rebound sub-chamber 48 to the compression sub-chamber 46 when the fluid flow rate and / or pressure differential between the compression sub-chamber 46 and the rebound sub-chamber 48 is less than a first threshold (e.g., a drain flow). Figure 6 This resistance is shown in the middle by the cross-section W of the curve CI. When the fluid flow rate and / or pressure differential is less than the first threshold, the check cup 76 at the first surface 30 can be in an un-flexed position.

[0098] Referring to Figure 7 When the fluid flow rate and / or pressure differential between the rebound sub-chamber 48 and the compression sub-chamber 46 is greater than the first threshold, the damper assembly 22 is shown moving toward the extended position. Fluid flow along the first fluid flow path FF1 moves the check cup 76 toward the first surface 30 of the piston 28 to a first flexed position, for example, abutting the bend 62, when the fluid flow rate and / or pressure differential is greater than the first threshold. Moving the check cup 78 toward the piston 28 reduces the size of the opening 84 between the check cup 76 and the first surface 30. Figure 8 This resistance provided by reducing the size of the opening 84 is shown in the middle by the cross-section X of the curve CI.

[0099] Referring to Figure 9The damper assembly 22 is shown moving toward the extended position when the fluid flow rate and / or pressure differential between the rebound sub-chamber 48 and the compression sub-chamber 46 is greater than a second threshold. The second threshold is greater than the first threshold. When the fluid flow rate and / or pressure differential is greater than the second threshold, the fluid flow along the first fluid flow path FF1 also moves the check disk 76 toward the first surface 30 of the piston 28 to a second flexed position, e.g., abutting the second portion 58 of the first surface 30 surrounding the first passage 34. Moving the check disk 76 to the second flexed position minimizes the size of the opening 86, e.g., to approximately equal the radial flow area of the orifice 106 of the orifice disk 38. Reducing and / or minimizing the size of the opening 86 reduces the defined area of the first fluid flow path FF1 and increases the resistance to movement of the corresponding damper assembly 22 by reducing the rate at which fluid can flow from the rebound sub-chamber 48 to the compression sub-chamber 46. Figure 10 This resistance is illustrated by the cross-section Y of the curve CI.

[0100] The second threshold can cause the amplitude of the curve CI to reach a predetermined amount of response force within a predetermined amount of time. The first threshold can be used to control the shape of the curve CI, e.g., the radius of curvature between the cross-section X and the cross-section Y of the curve CI. The predetermined amount can be based on, e.g., empirical testing, to optimize vehicle 20 performance and / or occupant comfort.

[0101] Referring to Figure 11 , the second fluid flow FF2 path defined by the damper assembly 22 is shown. The second fluid flow FF2 path is defined when the corresponding damper assembly 22 is moving toward the extended position and the fluid flow rate and / or pressure differential between the compression sub-chamber 46 and the rebound sub-chamber 48 is greater than a third threshold. The third threshold can be greater than the first threshold and the second threshold, such that the slope and / or amplitude of the curve CI does not exceed a predetermined amount. The predetermined amount can be based on, e.g., empirical testing, to optimize vehicle 20 performance and / or occupant comfort.

[0102] When the fluid flow rate and / or pressure differential is above the third threshold, the drain disk 130 and the spring disks 142a-142d at the second surface 32 are pushed away from the piston 28 and create an opening 134 therebetween. The second fluid flow FF2 path extends from the rebound sub-chamber 48 to the compression sub-chamber 46 via the second passage 68 and the opening 134 between the second surface 32 of the piston 28 and the drain disk 128. The second fluid flow FF2 path defines an area through which fluid can flow. The defined area of the second fluid flow FF2 path can include a plurality of sub-areas.

[0103] The combined defined area of the first fluid flow path FF1 and the second fluid flow FF2 path reduces the resistance to movement of the corresponding damper assembly 22 (relative to the defined area of only the first fluid flow path FF1) by increasing the rate at which fluid can flow from the rebound sub-chamber 48 to the compression sub-chamber 46.Figure 12 This resistance is illustrated by the cross section Z of curve CI.

[0104] Referring to Figure 13 illustrates third and fourth fluid flow paths FF3, FF4 defined by the damper assembly 22. The third and fourth fluid flow paths FF3, FF4 can be defined when the damper assembly 22 is moving toward the compression position.

[0105] The third fluid flow path FF3 extends from the compression sub-chamber 46 to the rebound sub-chamber 48 via the first passage 34 and an opening 86 between the piston 28 second surface 32 and the check disc 78. Figure 13 illustrates the check disc 78 in the second flexed position when the fluid flow rate and / or pressure differential between the compression sub-chamber 46 and the rebound sub-chamber 48 is above a second threshold.

[0106] The fourth fluid flow path extends from the compression sub-chamber 46 to the rebound sub-chamber 48 via the third passage 70 and an opening 132 between the piston 28 second surface 32 and the drain disc 130. The fourth fluid flow path can be defined when the damper assembly 22 is moving toward the compression position and the fluid flow rate and / or pressure differential between the compression sub-chamber 46 and the rebound sub-chamber 48 is above a third threshold.

[0107] Referring to Figure 14 illustrates curves CI and C2. Curve CI represents the response force provided by the damper assembly 22 moving at increasing velocities toward the extension position. Curve C2 represents the response force provided by the damper moving at increasing velocities toward the compression position. Various components of the damper assembly 22 can be configured to control curves CI, C2, i.e., control the amount of response force provided by the damper assembly 22 at various velocities.

[0108] The curves CI, C2 can be increased or decreased in slope and / or amplitude near the arrows A and A', for example, to provide tuning for low speed motion of the damper assembly 22. For example, increasing the steepness of the slope of the second portion 58 of the first surface 30, increasing the thickness of the fulcrum disk 72, increasing the stiffness of the check disk 76, and / or increasing the size of the orifices 104 of the orifice disk 36 can decrease the slope and / or amplitude of the curve CI near the arrow A. Similarly, increasing the steepness of the slope of the second portion 60 of the second surface 32, increasing the thickness of the fulcrum disk 74, increasing the stiffness of the check disk 78, and / or increasing the size of the orifices 106 of the orifice disk 38 can decrease the slope and / or amplitude of the curve C2 near the arrow A'. As another example, decreasing the steepness of the slope of the second portion 58 of the first surface 30, decreasing the thickness of the fulcrum disk 72, decreasing the stiffness of the check disk 76, and / or decreasing the size of the orifices 104 of the orifice disk 36 can increase the slope and / or amplitude of the curve CI near the arrow A. Similarly, decreasing the steepness of the slope of the second portion 60 of the second surface 32, decreasing the thickness of the fulcrum disk 74, decreasing the stiffness of the check disk 78, and / or decreasing the size of the orifices 106 of the orifice disk 38 can increase the slope and / or amplitude of the curve C2 near the arrow A'.

[0109] The curves CI, C2 can be increased or decreased in slope and / or amplitude near the arrows B and B'. For example, increasing the stiffness of the discharge disk 130 at the second surface 32 can increase the slope and / or amplitude of the curve CI near the arrow B. Similarly, increasing the stiffness of the discharge disk 128 at the first surface 30 can increase the slope and / or amplitude of the curve C2 near the arrow B'.

[0110] The curves CI, C2 can be increased or decreased in slope and / or amplitude near the arrows C and C', for example, to provide tuning for mid speed motion of the damper assembly 22. For example, decreasing the thickness of the rings 144, 146 can decrease the slope and / or amplitude of the curve CI near the arrows C and C'. As another example, increasing the thickness of the rings 144, 146 can increase the slope and / or amplitude of the curve CI near the arrows C and C'.

[0111] The curves CI, C2 can be increased or decreased in slope and / or amplitude near the arrows D and D'. For example, increasing the stiffness of the spring disks 142a-142d at the second surface 32 can increase the slope and / or amplitude of the curve CI near the arrow D. Similarly, increasing the stiffness of the discharge spring disks 140a-140d at the first surface 30 can increase the slope and / or amplitude of the curve C2 near the arrow D'. As another example, decreasing the stiffness of the spring disks 142a-142d at the second surface 32 can decrease the slope and / or amplitude of the curve CI near the arrow D. Similarly, decreasing the thickness of the spring disks 140a-140d at the first surface 30 can decrease the slope and / or amplitude of the curve C2 near the arrow D'.

[0112] Although the curves CI, C2 proximate to the various arrows A, A’, B, B’, C, C’, D, D’ are described separately, the curves CI, C2 can be controlled based on the cumulative effect of the configuration of the various components. For example, configuring the damper assembly 22 20 to control the curves CI, C2 proximate to the arrows A, A’ can also change the curves CI, C2 proximate to the other arrows B, B’, C, C’, D, D’.

[0113] The adjectives “first,” “second,” and “third” are used as identifiers and are not intended to indicate importance or order.

[0114] The present disclosure has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present disclosure are possible in light of the above teachings, and the present disclosure can be practiced otherwise than as specifically described.

Claims

1. A damper assembly comprising: a pressure tube defining a chamber; a body supported by the pressure tube, the body having a first surface and a second surface opposite the first surface and spaced apart from the first surface along an axis, the body defining a passage extending from the first surface to the second surface; and an orifice disc movable from a non-deflected position to a first deflected position and from the first deflected position to a second deflected position, the orifice disc in the non-deflected position spaced apart from the first surface radially outwardly and radially inwardly of the passage, the orifice disc in the first deflected position spaced apart from the first surface radially outwardly of the passage and abutting the first surface radially inwardly of the passage, and the orifice disc in the second deflected position abutting the first surface radially outwardly and radially inwardly of the passage; and a check disc covering orifices of the orifice disc, the check disc movable simultaneously with the orifice disc and from the non-deflected position to the first deflected position and from the first deflected position to the second deflected position to control a size of an opening between the check disc and the body.

2. The damper assembly of claim 1, wherein the orifice disc includes orifices at the passage.

3. The damper assembly of claim 1, further comprising a fulcrum disc between the body and the orifice disc.

4. The damper assembly of claim 3, wherein the fulcrum disc is radially inwardly of the passage.

5. The damper assembly of claim 1, wherein the first surface includes a first portion extending transverse to the axis and a second portion extending transverse to the axis and the first portion.

6. The damper assembly of claim 5, wherein the passage is at the second portion of the first surface.

7. The damper assembly of claim 1, wherein the first surface radially inwardly of the passage is spaced apart from the first surface radially outwardly of the passage along the axis.

8. The damper assembly of claim 1, wherein the orifice disc in the second deflected position abuts the first surface around the passage.

9. The damper assembly of any one of claims 1 to 8, wherein the body is a piston. ​

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