Pressure relief poppet valve for a suspension damper

Abstract

A damper having a pressure tube and an outer tube, a piston rod extending between a first piston rod end and a second piston rod end, and a piston mounted on the second piston rod end. The piston is disposed within the pressure tube to define a rebound chamber and a compression chamber. A reservoir chamber is positioned between the pressure tube and the outer tube, and an intake valve assembly within the outer tube abutting an end of the pressure tube defines at least one intermediate chamber arranged in fluid communication with at least one externally mounted electro-mechanical control valve. A rebound chamber pressure relief valve is provided to release excess fluid pressure in the rebound chamber in the form of a poppet valve positioned within the piston and piston rod end. A compression chamber pressure relief valve is provided to release excess fluid pressure in the compression chamber in the form of a poppet valve within the intake valve assembly. The damper provided minimizes cavitation noise when the pressure relief valves open.

Description

Technical Field

[0001] This application generally relates to dampers used in vehicle suspension systems. More specifically, this application relates to pressure relief lift valves in suspension dampers. Background Technology

[0002] This section provides background information related to the content of this application, which is not necessarily prior art.

[0003] Vehicles typically include dampers, used in conjunction with the suspension system, to absorb vibrations that occur while driving. To absorb vibrations, dampers are usually connected between the vehicle body and the vehicle's suspension system. A piston is located within the damper. The piston is connected to the vehicle body or suspension system via 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 damping fluid between a rebound chamber and a compression chamber, which are confined within the damper body, thereby generating a damping force that counteracts vibrations. By further restricting the flow of damping fluid between the rebound and compression chambers of the damper, the damper can generate even greater damping forces.

[0004] Dampers typically include one or more valves that control fluid flow during the extension and compression motion of a piston. Many current damper designs utilize externally mounted electromechanical valves to control extension and compression damping. However, the internal pressure of such systems can exceed design requirements. Therefore, passive (mechanical) relief valves are sometimes used to prevent excessive pressure within the damper's chambers; however, these relief valves often increase the damper's dead length and / or reduce its stroke, and also introduce unwanted noise. Therefore, improved relief valves are preferable. Summary of the Invention

[0005] This section provides a general overview of the application and is not a complete disclosure of its full scope or all its features.

[0006] According to one aspect of this application, a damper is provided. The damper includes a pressure tube extending coaxially about a longitudinal axis and extending longitudinally between a first pressure tube end and a second pressure tube end. The damper includes a piston slidably disposed within the pressure tube. The piston defines a springback chamber and a compression chamber within the pressure tube. The springback chamber is longitudinally positioned between the piston and the first pressure tube end, and the compression chamber is longitudinally positioned between the piston and the second pressure tube end. The piston extends longitudinally between a first piston end facing the springback chamber and a second piston end facing the compression chamber. A piston rod extends coaxially with the longitudinal axis between a first piston rod end and a second piston rod end. The second piston rod end is fixedly connected to the piston.

[0007] The damper also includes a spring chamber relief valve. The spring chamber relief valve includes one or more spring chamber relief passages extending from a first piston end to a second piston end, and a lift valve configured to open and close the spring chamber relief passages. The spring chamber relief valve also includes a valve cavity extending longitudinally between an open end and a closed end within a second piston rod end, and a valve seat surface longitudinally spaced from the open end of the valve cavity. The lift valve extends longitudinally between a first lift valve end and a second lift valve end. The first lift valve end is slidably received within the valve cavity. The second lift valve end includes a valve face positioned to move to contact and disengage from the valve seat surface, thereby opening and closing the spring chamber relief passages. The spring chamber relief valve also includes a spring positioned within the valve cavity that biases the lift valve toward the compression chamber.

[0008] According to another aspect of this application, the spring chamber pressure relief valve includes a lift valve, wherein the valve face on the second lift valve end includes a chamfered surface that extends annularly and is arranged at an angle relative to the longitudinal axis. Furthermore, the valve seat surface of the spring chamber pressure relief valve extends annularly and is arranged at an angle relative to the longitudinal axis. According to this aspect of the application, the chamfered surface of the valve face has a first outer diameter, and the valve seat surface has a second outer diameter smaller than the first outer diameter. Due to this geometry, when the lift valve is in the closed state, a portion of the chamfered surface on the valve face is exposed to the fluid in the spring chamber pressure relief passage and defines a surface that, when the fluid pressure in the spring chamber exceeds the discharge pressure threshold of the spring chamber pressure relief valve, acts on this surface, causing the lift valve to move to the open state.

[0009] According to another aspect of this application, the damper further includes an outer tube disposed around the pressure tube to define a reservoir chamber between the pressure tube and the outer tube. The outer tube extends longitudinally between a first outer tube end and a second outer tube end. According to this aspect of the application, the damper also includes an intake valve assembly, a build-up chamber, and a compression chamber relief valve. The intake valve assembly is positioned within the outer tube and extends longitudinally between a first intake valve assembly end and a second intake valve assembly end. The intake valve assembly includes at least one intermediate chamber in fluid communication with the compression chamber via an intermediate channel extending within / outside the intake valve assembly. The build-up chamber is longitudinally positioned between the intake valve assembly and the second outer tube end.

[0010] The compression chamber pressure relief valve includes one or more compression chamber pressure relief passages extending through the intake valve assembly between an intermediate passage and a accumulating chamber. The compression chamber pressure relief valve includes a valve cavity extending longitudinally between an open end and a closed end within the intake valve assembly, and a valve seat surface longitudinally spaced from the open end of the valve cavity. A lift valve of the compression chamber pressure relief valve extends longitudinally between a first lift valve end and a second lift valve end. The first lift valve end is slidably received within the valve cavity. The second lift valve end has a valve face positioned to move to contact and disengage from the valve seat surface, thereby opening and closing the compression chamber pressure relief passage. The compression chamber pressure relief valve also includes a spring positioned within the valve cavity that biases the lift valve toward the accumulating chamber.

[0011] The compression chamber pressure relief valve may also have a chamfered surface on the valve face. When the lift valve is in the closed state, the chamfered surface is exposed to the fluid in the compression chamber pressure relief passage and defines the surface. When the fluid pressure in the compression chamber exceeds the discharge pressure threshold of the compression chamber pressure relief valve, the fluid pressure in the compression chamber acts on the surface, causing the lift valve to move to the open state.

[0012] Advantageously, the construction and positioning of the spring chamber pressure relief valve within the piston and second piston rod ends adds spring chamber pressure relief (i.e., venting) functionality to the damper, exceeding the flow rate capacity of the intake valve assembly and external control valve, without reducing or limiting the damper's permissible stroke or increasing its overall length. Similarly, the construction and positioning of the compression chamber pressure relief valve within the intake valve assembly adds compression chamber pressure relief (i.e., venting) functionality to the damper, exceeding the flow rate capacity of the intake valve assembly and external control valve, without reducing or limiting the damper's permissible stroke or increasing its overall length. Furthermore, the geometry and chamfered surface of the valve face of the pressure relief valve described herein provide vortices for the fluid entering the outlet section of the pressure relief channel when the valve is open, minimizing cavitation noise generated when the pressure relief valve is open. Attached Figure Description

[0013] The accompanying drawings described herein are for illustrative purposes only, and not for all possible implementations, and are not intended to limit the scope of this application.

[0014] Figure 1 This is a side perspective view of an exemplary damper constructed according to the contents of this application;

[0015] Figure 2 It is a section taken along line 2-2. Figure 1 A side cross-sectional view of an exemplary damper is shown;

[0016] Figure 3 yes Figure 2 An enlarged side cross-sectional view of an exemplary damper is shown, including arrows illustrating the fluid flow path through an exemplary compression chamber relief valve of the damper during the compression stroke;

[0017] Figure 4 yes Figure 2 Another enlarged side cross-sectional view of the exemplary damper shown, including arrows, illustrates the fluid flow path through the exemplary springback chamber pressure relief valve of the damper during the extension / rebound stroke;

[0018] Figure 5A yes Figure 3 An enlarged side cross-sectional view of the exemplary spring chamber pressure relief valve shown is shown in the closed state.

[0019] Figure 5B yes Figure 4 An enlarged side cross-sectional view of the exemplary spring chamber pressure relief valve shown is shown in the open state.

[0020] Figure 6A yes Figure 4 An enlarged side cross-sectional view of an exemplary compression chamber pressure relief valve is shown, indicating that it is in the closed state;

[0021] Figure 6B yes Figure 3 An enlarged side cross-sectional view of the exemplary compression chamber pressure relief valve shown is shown in the open state.

[0022] Figure 7 yes Figure 1 Exploded perspective view of an exemplary intake valve assembly of an exemplary damper shown;

[0023] Figure 8 yes Figure 1 An exploded top view of an exemplary intake valve assembly of an exemplary damper; and

[0024] Figure 9 yes Figure 1 An enlarged side cross-sectional view of an exemplary intake valve assembly of an exemplary damper shown. Detailed Implementation

[0025] The embodiments will now be described more fully with reference to the accompanying drawings. Where possible, the same reference numerals will be used throughout the drawings to refer to the same or similar parts.

[0026] Embodiments will now be described more fully with reference to the accompanying drawings. Exemplary embodiments are provided to make this disclosure thorough and to fully express its scope to those skilled in the art. Numerous specific details, such as examples of specific components, apparatus, and methods, are set forth to provide a thorough understanding of embodiments of the present application. It will be apparent to those skilled in the art that the specific details are unnecessary, and that exemplary embodiments may be embodied in many different forms, none of which should be construed as limiting the scope of the present application. In some exemplary embodiments, well-known processes, well-known equipment structures, and well-known technologies have not been described in detail.

[0027] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may also include the plural forms unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having” are inclusive and thus specify the presence of the 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 should not be construed as requiring performance in a particular order discussed or described unless specifically determined otherwise. It should also be understood that additional or alternative steps may be employed.

[0028] When an element or layer is described as “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it can be directly engaged, connected to, or coupled to the other element or layer, or there may be intermediate elements or layers present. Conversely, when an element is described as “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intermediate elements or layers present. Other terms used to describe relationships between elements should be interpreted in a similar manner, such as “between” versus “directly between,” “adjacent” versus “directly adjacent,” and so on. As used herein, the term “and / or” includes any and all combinations of one or more of the related listed items.

[0029] Although the terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers, and / or portions, these elements, components, regions, layers, and / or portions should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or portion from another. Terms such as “first,” “second,” and other numerical terms used herein do not imply order or sequence unless the context clearly indicates otherwise. Therefore, the first element, component, region, layer, or portion discussed below may be referred to as the second element, component, region, layer, or portion without departing from the teachings of the exemplary embodiments.

[0030] Spatial relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” and “upper,” are used here to describe the relationship between one element or feature and another, as shown in the figure. Spatial relative terms can be used to include different orientations of the device in use or operation, as well as the orientations described in the figure. For example, if the device in the figure is flipped over, elements described as “below” or “beneath” will be oriented to be “above” other elements or features. Therefore, the term “below” in the example can include both above and below orientations. The device may have other orientations (rotated 90 degrees or other orientations), and the spatial relative descriptors used here can be interpreted accordingly.

[0031] Figures 1 to 4 An exemplary damper 112 for a vehicle (not shown) is illustrated. The damper 112 contains a fluid, such as hydraulic fluid or oil, and is not limited thereto. The damper 112 includes a pressure tube 122 extending longitudinally between a first pressure tube end 156 and a second pressure tube end 157. A piston 124 is slidably disposed within the pressure tube 122. The piston 124 defines a rebound chamber 126 and a compression chamber 128 within the pressure tube 122. Both the rebound chamber 126 and the compression chamber 128 contain the aforementioned fluid. The rebound chamber 126 is longitudinally positioned between the piston 124 and the first pressure tube end 156, while the compression chamber 128 is longitudinally positioned between the piston 124 and the second pressure tube end 157. The volumes of the rebound chamber 126 and the compression chamber 128 vary according to the movement of the piston 124. The piston 124 has a cylindrical surface that seals the interior of the pressure tube 122 and extends longitudinally between a first piston end 125 facing the springback chamber 126 and a second piston end 127 facing the compression chamber 128.

[0032] The damper 112 includes a piston rod 134. The piston rod 134 defines a longitudinal axis A and is coaxially aligned with the longitudinal axis A. The piston rod 134 extends longitudinally between a first piston rod end 135a and a second piston rod end 135b, the first piston rod end 135a being configured to connect to a component of the suspension system or the vehicle body, and the second piston rod end 135b being connected to a piston 124.

[0033] The damper 112 also includes an outer tube 136, which is annularly arranged around the pressure tube 122 and includes an inner cylindrical surface 129 facing and radially spaced from the pressure tube 122, and an outer cylindrical surface 131 opposite to the inner cylindrical surface 129. In some embodiments including the illustrated embodiment, the outer tube 136 is concentrically arranged around the pressure tube 122 about a longitudinal axis A. The outer tube 136 extends longitudinally between a first outer tube end 137 and a second outer tube end 139. A piston rod 134 extends longitudinally through the first outer tube end 137. The outer tube 136 includes a closed portion 145 located 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 connector 143 is mounted on the closed portion 145 of the outer tube 136. The connector 143 may be provided in the form of a hole, ring, threaded stud, or other connection structure and configured to connect to components of the suspension system or the vehicle body. Optionally, the spring seat 200 is mounted on the outer tube 136 and extends circumferentially from the outer tube 136 at a position adjacent to the first outer tube end 137. The spring seat 200 can be provided to configure the damper 112 for use in a helical arrangement, wherein the spring seat 200 supports one end of a helical spring of a vehicle suspension system (not shown).

[0034] The damper 112 includes a reservoir 138 disposed between a pressure tube 122 and an outer tube 136. A piston rod 134 extends longitudinally through a guide rod 141 located at a first outer tube end 137. Portions of the guide rod 141 mate with the first outer tube end 137 and the first pressure tube end 156. Just inside the guide rod 141, the first pressure tube end 156 includes one or more openings 202 providing fluid communication between the rebound chamber 126 and the reservoir 138. In other words, the reservoir 138 is arranged to be in fluid communication with the rebound chamber 126 through the opening 202 of the first pressure tube end 156.

[0035] The damper 112 also includes a cover 148 connected to the outer cylindrical surface 131 of the outer tube 136. For example, without limitation, the cover 148 may be welded to the outer cylindrical surface 131 of the outer tube 136, but is not limited thereto. A collection chamber 152 is defined between the cover 148 and the outer tube 136. Thus, according to this arrangement, the collection chamber 152 is located outside the outer tube 136 (i.e., radially outward). Optionally, a filling connector 203 may be provided on the cover 148 to provide a location for filling or refilling the collection chamber 152 with hydraulic fluid or oil.

[0036] The first control valve 164a and the second control valve 164b are externally mounted to the cover 148 on the outer pipe 136. Although other types of control valves can be used, in the illustrated embodiment, the first control valve 164a and the second control valve 164b are electromechanical valves. The operation of the first control valve 164a and the second control valve 164b will be explained in more detail below, but at a high level, the first control valve 164a and the second control valve 164b regulate two fluid flow paths that can deliver fluid into and out of the collection chamber 152. The first control valve 164a has a first control valve shaft VA1, and the second control valve 164b has a second control valve shaft VA2. The first control valve shaft VA1 and the second control valve shaft VA2 are parallel to each other and longitudinally spaced apart, circumferentially aligned with each other along the control valve alignment axis AA, and arranged perpendicular to the longitudinal axis A and the control valve alignment axis AA. In other words, both the first control valve shaft VA1 and the second control valve shaft VA2 intersect the longitudinal axis A and the control valve alignment axis AA.

[0037] In the illustrated example, the collection chamber 152 has a limited circumferential range that extends around the outer tube 136 in an arc 149 of less than or equal to 180 degrees. In other words, in the illustrated example, the collection chamber 152 extends longitudinally along the outer tube 136 on each side of the control valve alignment axis AA. The outer tube 136 has a total longitudinal length OL measured between the first outer tube end 137 and the second outer tube end 139, and the collection chamber 152 has a collection chamber length CL measured longitudinally between the first collector end 151 and the second collector end 153. The collection chamber length CL is shorter than the total length OL. In other words, the collection chamber 152 is shorter than the outer tube 136 and does not extend along the entire length of the outer tube 136.

[0038] See again Figures 7 to 9The damper 112 includes an intake valve assembly 154 disposed within the outer tube 136 and extending longitudinally between a first intake valve assembly end 176 and a second intake valve assembly end 178. The intake valve assembly 154 includes: an adapter body 130 located at the first intake valve assembly end 176; a first intake valve body 155a abutting against the adapter body 130; a second valve body 155b abutting against the first intake valve body 155a; a separator body 155c located at the second intake valve assembly end 178; and a retainer body 155d longitudinally positioned between the second intake valve body 155b and the separator body 155c in an abutting arrangement. The retainer body 155d includes a tubular rod 210 extending longitudinally toward the first intake valve assembly end 176 and defining an intermediate channel 158a therein. The adapter body 130 is press-fitted onto a second pressure tube end 157. Furthermore, the adapter body 130, the first intake valve body 155a, and the second intake valve body 155b slide on and are supported by the tubular rod 210 of the retainer body 155d. The retainer ring 211 engages with a circumferentially extending groove in the tubular rod 210 to fix the adapter body 130, the first intake valve body 155a, and the second intake valve body 155b to the tubular rod 210 of the retainer body 155d. The first intake valve body 155a, the second intake valve body 155b, and the separator body 155c abut against the inner cylindrical surface 129 of the outer tube 136, thereby defining the first intermediate chamber 159a and the second intermediate chamber 159b within the outer tube 136.

[0039] 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 separator body 155c. The accumulation chamber 162 is longitudinally disposed between the separator body 155c and the second outer pipe end 139. Therefore, the first intake valve body 155a forms a partition between the first intermediate chamber 159a and the liquid storage 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 separator body 155c forms a partition between the second intermediate chamber 159b and the accumulation chamber 162.

[0040] The intake valve assembly 154 also includes a first intake valve 165a mounted on a first intake valve body 155a and a second intake valve 165b mounted on a second intake valve body 155b. An intermediate channel 158a in the tubular rod 210 of the retainer body 155d extends longitudinally from the first intake valve assembly end 176 through the intake valve assembly 154, through the adapter body 130, through the first and second intake valve bodies 155a and 155b, and through the retainer body 155d to reach the second intake valve assembly end 178. Therefore, the intermediate channel 158a extends longitudinally through the intake valve assembly 154 and is arranged to be in fluid communication with the compression chamber 128 and the second intermediate chamber 159b.

[0041] The first intake valve 165a controls the fluid flow through the intake valve assembly 154 between the first intermediate chamber 159a and the liquid storage chamber 138, while the second intake valve 165b controls the fluid flow through the intake valve assembly 154 between the first intermediate chamber 159a and the second intermediate chamber 159b, which leads to the intermediate channel 158a and ultimately to the compression chamber 128.

[0042] 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 within the outer tube 136, extending between a closed end 173 adjacent to the second outer tube end 139 and an open end 174 adjacent to the intake valve assembly 154. The floating piston 161 is pre-installed within the accumulator sleeve 166 in a sliding fit. The pressurized chamber 163 is separated from the accumulator chamber 162 by the floating piston 161. Thus, the accumulator 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 gasoline, which acts to bias the floating piston 161 toward the intake valve assembly 154.

[0043] 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 the open end 174 of the accumulator sleeve 166 abuts against the separator body 155c of the intake valve assembly 154. Therefore, the intake valve assembly 154 is sandwiched between the open end 174 of the accumulator sleeve 166 and the second pressure tube end 157 of the pressure tube 122. With this arrangement, the first intake valve body 155a, the second intake valve body 155b, and the separator body 155c do not need to be mechanically connected to the outer tube 136 (e.g., by welding), because the intake valve assembly 154 is fixed in place by the accumulator sleeve 166 and the pressure tube 122.

[0044] refer to Figures 2 to 4The first control valve 164a has a first control valve inlet 170a arranged in fluid communication with a reservoir 138 between an inner tube 122 and an outer tube 136, and a first control valve outlet 172a arranged in fluid communication with a collection chamber 152. A first control valve port 140 in the outer tube 136 is arranged in fluid communication with the reservoir 138 and the first control valve inlet 170a and extends between them. The second control valve 164b has a second control valve inlet 170b arranged in fluid communication with a second intermediate chamber 159b, and a second control valve outlet 172b arranged in fluid communication with the collection chamber 152. A second control valve port 142 in the outer tube 136 is arranged in fluid communication with the second intermediate chamber 159b and the second control valve inlet 170b and extends between them. Therefore, the first control valve 164a regulates the fluid flow from the reservoir 138 to the collection chamber 152, and the second control valve 164b regulates the fluid flow from the second intermediate chamber 159b to the collection chamber 152.

[0045] One or more accumulator ports 144 in the outer tube 136 are arranged in fluid communication with and extend between the collection 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 extend between the collection chamber 152 and the first intermediate chamber 159a. In other words, the accumulation chamber 162 is in fluid communication with the collection chamber 152 through the accumulator ports 144 in the outer tube 136, while the first intermediate chamber 159a is in fluid communication with the collection chamber 152 through the open ports 146 in the outer tube 136. The accumulator ports 144 and open ports 146 in the outer tube 136 are provided in the form of open orifices, slots, or apertures that are not opened or closed by valves. Therefore, fluid can flow freely between the collection chamber 152 and the accumulation chamber 162, and between the collection chamber 152 and the first intermediate chamber 159a.

[0046] In the open state, the first control valve 164a allows fluid communication between the reservoir chamber 138 and the collection chamber 152. More specifically, the first control valve inlet 170a is in fluid communication with the reservoir chamber 138, and the first control valve outlet 172a is in fluid communication with the collection chamber 152. The first valve element 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 reservoir chamber 138 and the collection chamber 152, ultimately regulating the fluid flow from the springback chamber 126 to the compression chamber 128.

[0047] In the open state, the second control valve 164b allows fluid communication between the second intermediate chamber 159b and the collection 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 collection chamber 152. The second valve element 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 collection chamber 152, ultimately regulating the fluid flow from the compression chamber 128 to the reservoir chamber 138 and the accumulation chamber 162.

[0048] like Figure 3 As shown, when piston 124 moves toward intake valve assembly 154 during the compression stroke, the volume of compression chamber 128 decreases. Second control valve 164b is actuated to open during the compression stroke of damper 112 to regulate fluid flow from second intermediate chamber 159b to collector chamber 152. Specifically, the opening degree of second control valve 164b can be adjusted to modify the compression damping characteristics of damper 112. Simultaneously, first control valve 164a remains closed during the compression stroke of damper 112. Therefore, there is no direct fluid communication between reservoir chamber 138 and collector chamber 152 during the compression stroke.

[0049] During the compression stroke, a compression flow path P1 is defined within the damper 112. Fluid in the compression chamber 128 flows through the intermediate channel 158a in the first intake valve assembly 154 and enters the second intermediate chamber 159b. Fluid in the second intermediate chamber 159b flows to the second control valve inlet 170b and through the second control valve port 142 in the outer pipe 136. Since the second control valve 164b is open, fluid from the second control valve inlet 170b flows to the second control valve outlet 172b, and fluid from the second control valve outlet 172b flows into the collection chamber 152. Fluid flowing into the collection chamber 152 flows into the accumulation chamber 162 through the accumulation port 144 of the outer pipe 136, and then flows into the first intermediate chamber 159a through the open port 146 of the outer pipe 136. If the pressure difference between the first intermediate chamber 159a and the reservoir chamber 138 exceeds the breakage pressure of the first intake valve 165a, the first intake valve 165a will open, and fluid will flow into the reservoir chamber 138 through the first set of intake holes 158b in the first intake valve body 155a. Then, some fluid in the reservoir chamber 138 flows through the opening 202 in the first pressure tube end 156 and enters the springback chamber 126, increasing in volume during the compression stroke. Additionally, during the compression stroke, as the piston rod 134 moves a greater length into the springback chamber 126, the volume of fluid displaced by the piston rod 134 increases. The fluid displaced by the piston rod 134 (i.e., the piston rod volume) flows into the collecting chamber 152, through the accumulator port 144, and into the accumulator chamber 162, causing the floating piston 161 to move away from the intake valve assembly 154, increasing the size of the accumulator chamber 162.

[0050] like Figure 4 As shown, when piston 124 moves away from intake valve assembly 154 during the extension / rebound stroke, the fluid volume in compression chamber 128 increases. First control valve 164a is actuated to open during the extension stroke of damper 112 to regulate fluid flow from reservoir chamber 138 to collector chamber 152. Specifically, the degree of opening of first control valve 164a can be adjusted to modify the extension / rebound damping characteristics of damper 112. Simultaneously, second control valve 164b is closed during the extension stroke of damper 112. Therefore, there is no direct fluid communication between second intermediate chamber 159b and collector chamber 152 during the extension stroke.

[0051] During the extension / rebound stroke, a rebound flow path P2 is defined within the damper 112, wherein fluid in the rebound chamber 126 flows into the reservoir chamber 138 through the opening 202 in the first pressure tube end 156, and then the fluid in the reservoir chamber 138 flows to the first control valve inlet 170a and through the first control valve port 140 in the outer tube 136. Since the first control valve 164a is open, fluid flows from the first control valve inlet 170a to the first control valve outlet 172a, and the fluid from the first control valve outlet 172a flows into the collection chamber 152. The fluid from the collection chamber 152 flows into the first intermediate chamber 159a through the open port 146 of the outer tube 136. When the pressure difference between the first intermediate chamber 159a and the second intermediate chamber 159b exceeds the breakage pressure of the second intake valve 165b, the second intake valve 165b will open. Fluid in the first intermediate chamber 159a will flow through the second set of intake holes 158d in the second intake valve body 155b, through the second intermediate chamber 159b, through multiple channels 204 in the retainer body 155d, through the intermediate channel 158a in the first intake valve assembly 154, and into the compression chamber 128. Additionally, during the extension / rebound stroke, the volume displaced by the piston rod 134 (i.e., the piston rod volume) will decrease, so additional fluid flow must be supplied from the accumulation chamber 162 to compensate for the reduction in piston rod volume. Therefore, some fluid in the accumulation chamber 162 flows through the accumulator port 144 and into the collection chamber 152, where it joins the extension flow path P2. The net flow of fluid out of the accumulation chamber 162 causes the floating piston 161 to move toward the intake valve assembly 154, reducing the size of the accumulation chamber 162. Therefore, the intake valve assembly 154 allows fluid to flow in and out of the compression chamber 128 in both directions.

[0052] As previously described, 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 each other on the outer tube 136 along the control valve alignment axis AA. To minimize the overall height of the first control valve 164a and the second control valve 164b, a cover 148 can be externally mounted to the outer tube 136 such that the cover abuts / contacts with the outer cylindrical surface 131 of the outer tube 136 along the control valve alignment axis AA. According to this space-saving arrangement, the collection chamber 152 extends on both sides of the control valve alignment axis AA, while the accumulator port 144 and the open port 146 in the outer tube 136 are offset relative to the first control valve port 144 and the second control valve port 142, thereby circumferentially spaced apart from 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 divides the first control valve port 14 and the second control valve port 142 into two, but due to their offset arrangement, they do not divide the accumulator port 144 and the open port 146 into two, which allows the accumulator port 144 and the open port 146 to be in direct fluid communication with the collection chamber 152.

[0053] refer to Figures 2 to 4 and Figures 5A to 5B The piston 124 includes a spring chamber relief valve 300 to limit high internal pressure within the spring chamber 126. The piston 124 includes one or more spring chamber relief passages 304 that extend through the piston 124 at circumferentially spaced locations from the spring chamber 126 to the compression chamber 128.

[0054] The spring chamber pressure relief valve 300 is configured to allow fluid to flow in one direction from the spring chamber 126 to the compression chamber 128 through the spring chamber pressure relief passage 304 when the fluid pressure in the spring chamber 126 exceeds the discharge pressure threshold of the spring chamber pressure relief valve 300. In addition to the spring chamber pressure relief passage 304, the spring chamber pressure relief valve 300 also includes a valve chamber 308 extending longitudinally within the second piston rod end 135b and a poppet 310 extending longitudinally between a first poppet end 312 and a second poppet end 314. The first poppet end 312 is slidably received in the valve chamber 308, and the second poppet end 314 includes a valve face 316. The second poppet end 314 extends from the valve chamber 308, and the valve face 316 on the second poppet end 314 is configured to open and close the spring chamber pressure relief passage 304 in response to longitudinal movement of the poppet 310 in the valve chamber 308. The spring chamber relief valve 300 also includes a spring 318 positioned within the valve cavity 308, contacting the first lift valve end 312 and biasing the lift valve 310 toward the compression chamber 128. More specifically, the spring 318 of the spring chamber relief valve 300 applies a biasing force to the lift valve 310 in a longitudinal direction pointing away from the spring chamber 126, which defines a relief pressure threshold for the spring chamber relief valve 300. Although other configurations are possible, in the illustrated example, the spring 318 is a coil spring that extends helically within the valve cavity 308. Therefore, the lift valve 310 is configured to slide longitudinally relative to the valve cavity 308 and remain in a closed state (e.g., when the fluid pressure in the spring chamber 126 exceeds the relief pressure threshold of the spring chamber relief valve 300) within the valve cavity 308. Figure 3 and Figure 5A (As shown) Slide longitudinally to the open position of the spring chamber pressure relief valve (e.g.) Figure 4 and Figure 5B (As shown). Since the valve chamber 308 is located within the second piston rod end 135b, this arrangement of the spring chamber pressure relief valve 300 does not reduce the allowable stroke of the damper 112 or increase the total length OL of the damper 112.

[0055] The spring chamber pressure relief valve 300 also includes a seat component 320 connected to the piston 124 near the second piston end 127. While other configurations are possible, in the illustrated example, the seat component 320 is threaded to the second piston end 127. Regardless of the configuration, the seat component 320 of the spring chamber pressure relief valve 300 defines a seat surface 322. A valve chamber 308 extends longitudinally within the second piston rod end 135b between an open end 324 and a closed end 326. A spring 318 extends longitudinally within the valve chamber 308 and contacts the closed end 326 of the valve chamber 308 and the first lift valve end 312. The seat surface 322 is longitudinally spaced from the open end 324 of the valve chamber 308 and arranged to align with a valve face 316 on the second lift valve end 314, positioning the valve face 316 to move to contact or disengage from the seat surface 322, thereby opening and closing the spring chamber pressure relief passage 304.

[0056] The spring chamber pressure relief passage 304 includes an inlet section 328 and an outlet section 330. When the lift valve 310 is in the closed state of the spring chamber pressure relief valve, the inlet section and the outlet section are separated by the valve face 316 on the valve seat surface 322 (e.g., Figure 3 and Figure 5A (As shown). The inlet section 328 of the spring chamber pressure relief passage 304 is arranged in fluid communication with the spring chamber 126, and the outlet section 330 of the spring chamber pressure relief passage 304 is arranged in fluid communication with the compression chamber 128. Although other configurations are possible, in the illustrated example, the inlet section 328 of the spring chamber pressure relief passage 304 is formed by a plurality of circumferentially spaced holes in the piston 124, which open into a common inlet cavity 332 located between the valve seat component 320 and portions of the piston 124 near the second piston rod end 135b. The holes in the piston 124 and the common inlet cavity 332 together constitute the inlet section 328 of the spring chamber pressure relief passage 304. In the illustrated example, the outlet section 330 of the spring chamber pressure relief passage 304 is provided as a single hole coaxially aligned with the longitudinal axis A and extending through the valve seat component 320 to the compression chamber 128.

[0057] from Figure 5A and Figure 5B As can be seen, the valve face 316 on the second lift valve end 314 includes a chamfered surface 334 extending annularly on the second lift valve end 314. The chamfered surface 334 is arranged at an angle relative to the longitudinal axis A. The valve seat surface 322 extends annularly on the valve seat component 320 and around the outlet section 330 of the spring chamber pressure relief passage 304. The valve seat surface 322 is also arranged at an angle relative to the longitudinal axis A and is generally complementary in shape to the chamfered surface 334 on the second lift valve end 314.

[0058] The chamfered surface 334 on the valve face 316 has a first outer diameter OD1, and the valve seat surface 322 on the valve seat component 320 has a second outer diameter OD2, which is smaller than the first outer diameter OD1, such that when the lift valve 310 is in the closed state of the spring chamber pressure relief valve, a portion of the chamfered surface 334 on the valve face 316 is exposed to the fluid in the inlet section 328 of the spring chamber pressure relief passage 304. Figure 3 and Figure 5A When the fluid pressure in the rebound chamber 126 exceeds the release pressure threshold of the rebound chamber relief valve 300, a surface is defined, and the fluid pressure in the common inlet 332 (and therefore the rebound chamber 126) acts on this surface, causing the lift valve 310 to move to the open state of the rebound chamber relief valve. Figure 4 and Figure 5B ).

[0059] Still referencing Figure 5A and Figure 5B The chamfered surface 334 of the valve face 316 has a first inner diameter ID1, and the valve seat surface 322 of the valve seat component 320 has a second inner diameter ID2, which is equal to the first inner diameter ID1 of the chamfered surface 334 on the valve face 316. Furthermore, the outlet section 330 of the spring chamber pressure relief passage 304 has a third diameter D3, which is larger than the second inner diameter ID2 of the valve seat surface 322, thereby providing one or more vortices 338 (e.g., when the lift valve 310 is in the spring chamber pressure relief valve open state) for the fluid flow entering the outlet section 330 of the spring chamber pressure relief passage 304. Figure 4 and Figure 5B (As shown). The vortex 338 provides an oil gap space around the jet / main stream of fluid passing through the spring chamber pressure relief valve 300, in which the fluid / oil exhibits circulating / turbulent flow, which helps to minimize noise caused by cavitation or cavitation when the spring chamber pressure relief valve 300 is open.

[0060] The lift valve 310 includes a longitudinally extending through-hole 340 between a first lift valve end 312 and a second lift valve end 314, which allows fluid to flow through the lift valve 310 and achieve pressure equalization between the valve chamber 308 at the second piston rod end 135b, the outlet section 330 of the spring chamber pressure relief passage 304, and thus the compression chamber 128. Therefore, the discharge pressure threshold of the spring chamber pressure relief valve 300 is defined by a biasing force applied to the lift valve 310 by a spring 318. The lift valve 310 may optionally include one or more sealing rings 342 that extend annularly around the lift valve 310 and sealably engage with the valve chamber 308 without impeding sliding movement of the lift valve 310 within the valve chamber 308.

[0061] The first lift valve end 312 is configured to slide longitudinally within the valve cavity 308, thereby causing the valve surface 316 on the second lift valve end 314 to move away from the valve seat surface 322 of the valve seat component 320, and limiting the opening state of the rebound chamber pressure relief valve when the fluid pressure in the rebound chamber 126 exceeds the relief pressure threshold of the rebound chamber pressure relief valve 300. Figure 4 and Figure 5B In this state, the spring chamber pressure relief valve 300 allows fluid flow B2 to flow from the spring chamber 126 through the spring chamber pressure relief passage 304 and out to the compression chamber 128.

[0062] refer to Figures 2 to 4 and Figures 6A to 6B The damper 112 also includes a compression chamber relief valve 400 to limit high internal pressure within the compression chamber 128. The intake valve assembly 154 includes one or more compression chamber relief passages 404 that extend through a separator body 155c of the intake valve assembly 154 between an intermediate passage 158a and a accumulator chamber 162. The compression chamber relief valve 400 is configured to allow fluid to flow unidirectionally from the intermediate passage 158a through the compression chamber relief passage 404 to the accumulator chamber 162 when the fluid pressure in the compression chamber 128 exceeds a discharge pressure threshold of the compression chamber relief valve 400.

[0063] In addition to the compression chamber pressure relief passage 404, the compression chamber pressure relief valve 400 also includes a valve housing 402 extending longitudinally within an intermediate passage 158a. The valve housing 402 has a tubular shape, defining a valve cavity 408 having an open end 424 and a closed end 426. However, it should be understood that other arrangements are possible, in which the valve housing 402 is omitted, and one or more components of the intake valve assembly 154 form the valve cavity 408. The compression chamber pressure relief valve 400 further includes a lift valve 410 extending longitudinally between a first lift valve end 412 and a second lift valve end 414. The first lift valve end 412 is slidably received in the valve cavity 408, and the second lift valve end 414 includes a valve face 416. The second lift valve end 414 extends out of the valve cavity 408, and the valve face 416 on the second lift valve end 414 is configured to open and close the compression chamber pressure relief passage 404 in response to longitudinal movement of the lift valve 410 in the valve cavity 408. The compression chamber pressure relief valve 400 also includes a spring 418 positioned within the valve chamber 408, which contacts the first lift valve end 412 and biases the lift valve 410 toward the accumulation chamber 162. More specifically, when the compression chamber pressure relief valve 400 is in the compression chamber pressure relief valve closed state (e.g., Figure 4 and Figure 6A As shown), the spring 418 pushes the second lift valve end 414 toward the separator body 155c to prevent fluid from flowing through the compression chamber pressure relief passage 404.

[0064] A spring 418 of the compression chamber relief valve 400 extends longitudinally within the valve chamber 408, contacting the closed end 426 of the valve chamber 408 and the first lift valve end 412. Therefore, the spring 418 applies a biasing force to the lift valve 410 in the longitudinal direction away from the compression chamber 128, which defines the relief pressure threshold of the compression chamber relief valve 400. Although other configurations are possible, in the illustrated example, the spring 418 is a coil spring that extends helically within the valve chamber 408. Therefore, when the fluid pressure in the compression chamber 128 exceeds the relief pressure threshold of the compression chamber relief valve 400, the lift valve 410 is configured to slide longitudinally relative to the valve chamber 408 and be in the closed state (e.g., from the compression chamber relief valve) within the valve chamber 408. Figure 4 and Figure 6A (As shown) Slide longitudinally to the open position of the spring chamber pressure relief valve (e.g.) Figure 3 and Figure 6B (As shown). Since the valve chamber 408 is located inside the intake valve assembly 154, this arrangement of the compression chamber relief valve 400 does not reduce the allowable stroke of the damper 112, nor does it increase the total length OL of the damper 112.

[0065] The compression chamber relief valve 400 also includes a seat component 420 connected to the divider body 155c. Although other configurations are possible, in the illustrated example, the seat component 420 is threadedly connected to the divider body 155c. Regardless of the configuration, the seat component 420 of the compression chamber relief valve 400 defines a seat surface 422. The seat surface 422 is longitudinally spaced from the open end 424 of the valve chamber 408 and arranged to align with a valve face 416 on the second lift valve end 414, thereby positioning the valve face 416 to move to contact and disengage from the seat surface 422, thereby opening and closing the compression chamber relief passage 404.

[0066] The compression chamber pressure relief passage 404 includes an inlet section 428 and an outlet section 430. When the lift valve 410 is in the closed state of the compression chamber pressure relief valve, the inlet section 428 and the outlet section 430 are separated by the valve surface 416 on the valve seat surface 422 (e.g., Figure 4 and Figure 6A(As shown). The inlet section 428 of the compression chamber relief passage 404 is arranged in fluid communication with the intermediate passage 158a and thus with the compression chamber 128, and the outlet section 430 of the compression chamber relief passage 404 is arranged in fluid communication with the accumulation chamber 162. Although other configurations are possible, in the illustrated example, the inlet section 428 of the compression chamber relief passage 404 is formed by a plurality of circumferentially spaced holes in the separator body 155c, which open into a common inlet cavity 432 located between the valve seat component 420 and various parts of the separator body 155c. The holes in the separator body 155c and the common inlet cavity 432 together constitute the inlet section 428 of the compression chamber relief passage 404. In the illustrated example, the outlet section 430 of the compression chamber relief passage 404 is provided as a single hole coaxially aligned with the longitudinal axis A and extending through the valve seat component 420 to the accumulation chamber 162.

[0067] like Figure 6A and Figure 6B As shown, the valve face 416 on the second lift valve end 414 includes a chamfered surface 434 extending annularly on the second lift valve end 414. The chamfered surface 434 is arranged at an angle relative to the longitudinal axis A. The valve seat surface 422 extends annularly on the valve seat component 420 and around the outlet section 430 of the compression chamber pressure relief passage 404. The valve seat surface 422 is also arranged at an angle relative to the longitudinal axis A, and its shape is complementary to that of the chamfered surface 434 on the second lift valve end 414.

[0068] The chamfered surface 434 on the valve face 416 has a first outer diameter OD1, and the valve seat surface 422 on the valve seat component 420 has a second outer diameter OD2 smaller than the first outer diameter OD1. Thus, when the lift valve 410 is in the closed state of the compression chamber pressure relief valve, a portion of the chamfered surface 434 on the valve face 416 is exposed to the fluid in the inlet section 428 of the compression chamber pressure relief passage 404. Figure 4 and Figure 6A ), and defines a surface that, when the fluid pressure in the compression chamber 128 exceeds the discharge pressure threshold of the compression chamber relief valve 400, is acted upon by the fluid pressure in the common inlet 432 (and therefore the compression chamber 128), causing the lift valve 410 to move to the compression chamber relief valve open state. Figure 3 and Figure 6B ).

[0069] Still referencing Figure 6A and Figure 6BThe chamfered surface 434 of the valve face 416 has a first inner diameter ID1, and the valve seat surface 422 of the valve seat component 420 has a second inner diameter ID2, which is equal to the first inner diameter ID1 of the chamfered surface 434 on the valve face 416. Furthermore, the outlet section 430 of the compression chamber pressure relief passage 404 has a third diameter D3, which is larger than the second inner diameter ID2 of the valve seat surface 422, thereby providing one or more vortices 438 (e.g., when the lift valve 410 is in the compression chamber pressure relief valve open state) for the fluid flow entering the outlet section 430 of the compression chamber pressure relief passage 404. Figure 3 and Figure 6B (As shown). The vortex 438 provides an oil gap space around the jet / main stream of fluid passing through the compression chamber relief valve 400, in which the fluid / oil exhibits circulating / turbulent flow, which helps to minimize noise caused by cavitation or cavitation when the compression chamber relief valve 400 is open.

[0070] The lift valve 410 includes a longitudinally extending through-hole 440 between a first lift valve end 412 and a second lift valve end 414, which allows fluid to flow through the lift valve 410 and achieve pressure equalization between the valve cavity 408 and the outlet section 430 of the compression chamber relief passage 404, and thus with the accumulation chamber 162. Therefore, the discharge pressure threshold of the compression chamber relief valve 400 is defined by a biasing force applied to the lift valve 410 by a spring 418. The lift valve 410 may optionally include one or more sealing rings 442 that extend annularly around the lift valve 410 and seal against the valve cavity 408 without impeding sliding movement of the lift valve 410 within the valve cavity 408.

[0071] The first lift valve end 412 is configured to slide longitudinally within the valve chamber 408, thereby causing the valve surface 416 on the second lift valve end 414 to move away from the valve seat surface 422 of the valve seat component 420, and limiting the opening state of the compression chamber relief valve when the fluid pressure in the compression chamber 128 exceeds the relief pressure threshold of the compression chamber relief valve 400. Figure 3 and Figure 6B In this state, the compression chamber pressure relief valve 400 allows fluid flow B1 from the compression chamber 128 through the compression chamber pressure relief passage 404 and out to the accumulation chamber 162.

[0072] refer to Figures 7 to 9The first intake valve body 155a and the second intake valve body 155b of the intake valve assembly 154 are configured as ventilation discs. The first intake valve body 155a includes a first central hole 206a extending through the first intake valve body 155a. A first set of intake holes 158b are arranged circumferentially (i.e., radially outward) around the first central hole 206a. The second intake valve body 155b includes a second central hole 206b extending through the second intake valve body 155b. A second set of intake holes 158d are arranged circumferentially (i.e., radially outward) around the second central hole 206b. The adapter body 130 and the retainer body 155d each have a cylindrical hub portion that directly abuts against one of the first intake valve body 155a and the second intake valve body 155b, and also have a disc-shaped flange portion for retaining the first intake valve 165a and the second intake valve 165b, such that both the adapter body 130 and the retainer body 155d have a cap-like shape. Furthermore, the adapter body 130 and the retainer body 155d each have a third center hole 206c and a fourth center hole 206d. The first center hole 206a in the first intake valve body 155a, the second center hole 206b in the second intake valve body 155b, the third center hole 206c in the adapter body 130, and the fourth center hole 206d in the retainer body 155d are aligned with each other and coaxially aligned with the central longitudinal axis A of the damper 112. The tubular rod 210 of the retainer body 155d extends through a first central hole 206a in the first intake valve body 155a, a second central hole 206b in the second intake valve body 155b, a third central hole 206c in the adapter body 130, and a fourth central hole 206d in the retainer body 155d. The fourth central hole 206d in the retainer body 155d defines an intermediate channel 158a for the intake valve assembly 154. The retainer ring 211 engages with a circumferentially extending groove in the tubular rod 210 of the retainer body 155d near the first intake valve assembly end 176, acting as a stop to prevent the adapter body 130 and the first and second intake valve bodies 155a and 155b from sliding longitudinally on the tubular rod 210 of the retainer body 155d after final assembly.

[0073] Therefore, before the outer tube 136 of the damper 112 is inserted, the adapter body 130 and the first intake valve body 155a and the second intake valve body 155b can be pre-assembled onto the tubular rod 210 of the retainer body 155d. By using the retainer ring 211, the adapter body 130 and the first intake valve body 155a and the second intake valve body 155b can be pre-loaded onto the tubular rod 210 of the retainer body 155d, thereby providing a preload on the first spring plate assembly 167a and the second spring plate assembly 167b without causing the pre-assembled components to separate. However, it should be understood that the retainer ring 211 can be omitted, and the tubular rod 210 of the retainer body 155d can be hammered or otherwise treated to produce outwardly flared, mechanically deformed ends, thereby securing the components of the pre-assembled part together before the pre-assembled part is inserted into the outer tube 136 of the damper 112. Regardless of the method, the manufacture and assembly of the damper 112 is simpler, more efficient, and more economical because the intake valve assembly 154 and the accumulator insert 160 can be pre-assembled before being installed into the outer tube 136.

[0074] The first intake valve 165a controls the flow of fluid through a first set of intake ports 158b between the first intermediate chamber 159a and the reservoir chamber 138. 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 set of spring plates 167a held between the adapter body 130 and the first intake valve body 155a. In operation, the first set of spring plates 167a opens and closes the first set of intake ports 158b by bending toward and away from the first intake valve body 155a according to the pressure difference between the first intermediate chamber 159a and the reservoir chamber 138. Therefore, the first intake valve 165a acts as a one-way valve, allowing fluid to flow only in one direction from the first intermediate chamber 159a to the reservoir chamber 138. This one-way flow through the first intake valve 165a occurs during the compression stroke as the piston 124 moves toward the intake valve assembly 154.

[0075] The second intake valve 165b controls the flow of fluid through a second set of intake ports 158d between the first intermediate chamber 159a and the second intermediate chamber 159b. 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 set of spring plates 167b held between the second intake valve body 155b and the retainer body 155d. In operation, the second set of spring plates 167b opens and closes the second set of intake ports 158d by bending toward and away from the second intake valve body 155b according to the pressure difference between the first intermediate chamber 159a and the second intermediate chamber 159b. The second intake valve 165b acts as a one-way valve, allowing fluid to flow only in one direction from the first intermediate chamber 159a and the second intermediate chamber 159b. This one-way flow through the second intake valve 165b occurs during the extension stroke of the piston 124 moving away from the intake valve assembly 154. The retainer body 155d includes a plurality of teeth 208 arranged to abut against the separator body 155c. These teeth 208 are circumferentially spaced to define a plurality of channels 204 within the retainer body 155d. The channels 204 in the retainer body 155d extend radially outward away from the central longitudinal axis A, thus allowing fluid to flow between the second intermediate chamber 159b and the intermediate channel 158a.

[0076] The rebound and compression damping rates of damper 112 can be dynamically controlled and adjusted between soft and hard limits by applying current to externally mounted electromechanical control valves 164a, 164b. However, due to fluid flow rate limitations through damper 112 and control valves 164a, 164b, there is an interrelationship between soft and hard limits. This means that when the damping rate of damper 112 approaches or is at the hard / upper limit of the adjustable damping rate range, the pressure inside rebound chamber 126 and compression chamber 128 may sometimes exceed design limits. The rebound chamber relief valve 300 and compression chamber relief valve 400 described herein release excess pressure in rebound chamber 126 and compression chamber 128, ensuring that the fluid pressure does not exceed design limits, improving safety, durability, and performance without consuming additional space / dead length inside damper 112. This would reduce the usable travel distance of damper 112 or increase its total length OL. In other words, the spring chamber pressure relief valve 300 and the compression chamber pressure relief valve 400 described herein are particularly advantageous because they minimize the additional dead zone typically associated with internal pressure relief (i.e., venting) valves.

[0077] While various aspects of this application have been specifically shown and described with reference to the above embodiments, those skilled in the art will understand that various additional embodiments can be conceived by modifying the disclosed damper without departing from the spirit and scope of the disclosure. Such embodiments should be understood to fall within the scope of this application as defined by the claims and any equivalents thereof.

Claims

1. A damper, comprising: A pressure tube, which extends coaxially about a longitudinal axis and extends longitudinally between a first pressure tube end and a second pressure tube end. A piston, slidably disposed within the pressure tube, defining a springback chamber and a compression chamber, the piston extending longitudinally between a first piston end facing the springback chamber and a second piston end facing the compression chamber; A piston rod extends coaxially about the longitudinal axis and longitudinally between a first piston rod end and a second piston rod end, wherein the second piston rod end is fixedly connected to the piston. as well as A spring-loaded chamber pressure relief valve includes: at least one spring-loaded chamber pressure relief passage extending through the piston from a first piston end to a second piston end; a valve cavity extending longitudinally between an open end and a closed end located within the second piston rod end; a valve seat surface longitudinally spaced from the open end of the valve cavity; a lift valve extending longitudinally between a first lift valve end and a second lift valve end, the first lift valve end being slidably received within the valve cavity, the second lift valve end having a valve face positioned to move to contact and disengage from the valve seat surface, thereby opening and closing the at least one spring-loaded chamber pressure relief passage; and a spring positioned within the valve cavity, the spring biasing the lift valve toward the compression chamber.

2. The damper of claim 1, wherein the spring of the rebound chamber pressure relief valve applies a biasing force to the lift valve, the biasing force defining a discharge pressure threshold of the rebound chamber pressure relief valve, and wherein the lift valve of the rebound chamber pressure relief valve is configured to slide longitudinally from a closed state to an open state when the fluid pressure in the rebound chamber exceeds the discharge pressure threshold of the rebound chamber pressure relief valve.

3. The damper according to claim 2, wherein the valve face on the lift valve of the spring chamber pressure relief valve includes an annularly extending chamfered surface, the chamfered surface being arranged at an angle relative to the longitudinal axis, and wherein, The valve seat surface of the rebound chamber pressure relief valve extends in a ring and is also arranged at an angle relative to the longitudinal axis.

4. The damper according to claim 3, wherein the chamfered surface of the valve face of the rebound chamber pressure relief valve has a first outer diameter, and the valve seat surface has a second outer diameter, the second outer diameter being smaller than the first outer diameter, such that when the lift valve is in the closed state of the rebound chamber pressure relief valve, a portion of the chamfered surface on the valve face is exposed to the fluid in the at least one rebound chamber pressure relief channel, and a surface is defined when the fluid pressure in the rebound chamber exceeds the discharge pressure of the rebound chamber pressure relief valve, the fluid pressure in the rebound chamber acting on the surface, causing the lift valve to move to the open state of the rebound chamber pressure relief valve.

5. The damper according to claim 4, wherein the chamfered surface of the valve face of the rebound chamber pressure relief valve has a first inner diameter, and the valve seat surface has a second inner diameter, the second inner diameter being equal to the first inner diameter of the chamfered surface on the valve face.

6. The damper of claim 5, wherein the at least one spring chamber pressure relief channel comprises an inlet section and an outlet section, wherein when the lift valve is in the closed state of the spring chamber pressure relief valve, the inlet section and the outlet section are separated by a valve face closure on the valve seat surface, wherein the inlet section is arranged in fluid communication with the spring chamber, the outlet section is arranged in fluid communication with the compression chamber, and wherein the outlet section of the at least one spring chamber pressure relief channel has a third diameter, the third diameter being larger than the second inner diameter of the valve seat surface, to provide vortices for fluid flow entering the outlet section when the lift valve is in the open state of the spring chamber pressure relief valve, thereby minimizing noise generated by cavitation.

7. The damper of claim 6, wherein the piston includes a valve seat received in the second piston end and defines the outlet section of the at least one spring chamber pressure relief passage and the valve seat surface extending circumferentially around the outlet section.

8. The damper according to claim 2, wherein the spring of the spring chamber pressure relief valve extends longitudinally between the closed end of the valve chamber and the first lift valve end and contacts the closed end of the valve chamber and the first lift valve end.

9. The damper according to claim 1, further comprising: An outer tube is disposed around the pressure tube to define a liquid storage chamber between the pressure tube and the outer tube, the outer tube extending longitudinally between a first outer tube end and a second outer tube end; An intake valve assembly is located inside the outer tube and extends longitudinally between a first intake valve assembly end and a second intake valve assembly end. The intake valve assembly includes at least one intermediate chamber configured to be in fluid communication with the compression chamber via an intermediate channel extending within the intake valve assembly. An accumulation chamber, the accumulation chamber being longitudinally positioned between the intake valve assembly and the second outer pipe end; as well as A compression chamber pressure relief valve includes: at least one compression chamber pressure relief passage extending through the intake valve assembly between the intermediate passage and the accumulation chamber; a valve cavity extending longitudinally between an open end and a closed end within the intake valve assembly; a valve seat surface longitudinally spaced from the open end of the valve cavity; a lift valve extending longitudinally between a first lift valve end and a second lift valve end, the first lift valve end being slidably received within the valve cavity, and the second lift valve end having a valve face positioned to move to contact and disengage from the valve seat surface, thereby opening and closing the at least one compression chamber pressure relief passage; and a spring positioned within the valve cavity, the spring biasing the lift valve toward the accumulation chamber.

10. The damper of claim 9, wherein the spring of the compression chamber relief valve applies a biasing force to the lift valve, the biasing force defining a discharge pressure threshold of the compression chamber relief valve, and wherein the lift valve of the compression chamber relief valve is configured to slide longitudinally from a closed state to an open state when the fluid pressure in the compression chamber exceeds the discharge pressure threshold of the compression chamber relief valve.

11. The damper of claim 10, wherein the intermediate channel in the intake valve assembly extends coaxially with the longitudinal axis, and wherein the compression chamber relief valve includes a valve housing that extends longitudinally within the intermediate channel and defines the valve cavity therein.

12. The damper of claim 11, wherein the valve face on the lift valve of the compression chamber relief valve includes a chamfered surface that extends annularly and is arranged at an angle relative to the longitudinal axis, and wherein the valve seat surface of the compression chamber relief valve extends annularly and is arranged at an angle relative to the longitudinal axis.

13. The damper of claim 12, wherein the intake valve assembly comprises: An adapter body located at the end of the first intake valve assembly, the adapter body abutting against the end of the second pressure pipe; The separator body located at the end of the second intake valve assembly; A retainer body adjacent to the separator body, the retainer body including a tubular rod extending longitudinally toward the first intake valve assembly end to define the intermediate channel; and at least one intake valve body longitudinally positioned between the adapter body and the separator body, wherein the separator body and the at least one intake valve body abut against the inner cylindrical surface of the outer tube, wherein the at least one intake valve body includes an intake valve that controls fluid flow through at least one intake port in the at least one intake valve body, wherein the at least one compression chamber pressure relief channel extends through the separator body of the intake valve assembly and includes an inlet section and an outlet section, the inlet section being arranged in fluid communication with the intermediate channel or the at least one intermediate chamber, the outlet section being arranged in fluid communication with the accumulation chamber, and wherein the valve seat surface of the compression chamber pressure relief valve is located on the separator body.

14. The damper of claim 9, wherein the lift valve of the compression chamber relief valve includes a longitudinally extending through-hole between the first lift valve end and the second lift valve end, allowing fluid to flow between the valve chamber and the outlet section of the at least one compression chamber relief passage, and thus between the fluid chamber and the accumulation chamber, and to achieve pressure equalization.

15. The damper of claim 1, wherein the spring chamber pressure relief valve includes a lift valve comprising a longitudinally extending through-hole between the first lift valve end and the second lift valve end, allowing fluid to flow between the valve chamber in the second piston rod end and the outlet section of the at least one spring chamber pressure relief passage, and thus between the at least one spring chamber pressure relief passage and the compression chamber, and to achieve pressure equalization.

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