Patent Description:
The dampers control movement of the wheels by limiting fluid flow past a piston of the damper. The fluid flows past the piston, e.g., via passages of the piston, when the damper is moved toward a compressed or extended position. The passages may have a fixed opening size. Resistance to movement is provided by the passages limiting an amount of fluid that flows therethrough. The resistance to movement may increase exponentially as movement speed is increased.

Discs may be used to control flow of fluid though the passages, e.g., by flexing or translating to increase or decrease a size of an opening at one end of the passage. Changing the opening size may change force response characteristics of the damper assembly. For example, increasing the opening size may decrease resistance to movement and decreasing the opening size may increase resistance to movement.

<CIT> discloses a piston valve arrangement for a vibration damper. In a high frequency mode, damping force control is achieved by an open channel that is always open. In a low frequency mode, a guide arrangement moves downward due to an increase in a pressure of a first pressure chamber by a fluid moving through an inlet hole of the first pressure chamber.

In accordance with the present invention, a damper assembly as set forth in claim <NUM> is provided. Further embodiments of the invention are claimed in the dependent claims. A damper assembly provides variable and tunable resistance and may be configured to provide a desired a responsive force that is resistant to movement of the damper assembly depending on a speed and direction of the movement, e.g., toward an extended or compressed position. For example, one or more orifice discs, check discs, blow off discs, may regulate fluid flow through a passage, e.g., by controlling an amount of area, and a rate of change of such area, though which fluid may flow.

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 and spaced 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 disc movable from an unflexed position to a first flexed position and movable from the first flexed position to a second flexed position. The orifice disc in the unflexed position is spaced from the first surface radially outward and radially inward of the passage. The orifice disc in the first flexed position is spaced from the first surface radially outward of the passage and abuts the first surface radially inward of the passage. The orifice disc in the second flexed position abuts the first surface radially outward and radially inward of the passage.

The orifice disc includes an orifice at the passage.

The orifice disc may include an outer edge and the orifice may extend radially inward from the outer edge.

The orifice may be in fluid communication with the passage when the orifice disc is in the second flexed position.

The damper assembly may include a check disc covering the orifice.

The orifice disc may be between the body and the check disc.

The damper assembly may include a fulcrum disc between the body and the orifice disc.

The fulcrum disc may be radially inward of the passage.

The first surface may include a first portion that extends transversely relative to the axis and a second portion that extends transversely relative to the axis and the first portion.

The first portion of the first surface may extend perpendicular relative to the axis.

The first portion of the first surface may be radially inward of the second portion of the first surface.

The second portion may extend away from the first portion and toward the second surface.

The passage may be at the second portion of the first surface.

The first surface radially inward of the passage may be spaced along the axis from the first surface radially outward of the passage.

The body may divide the chamber into a compression sub-chamber and a rebound sub-chamber, the first surface opposite the compression sub-chamber.

The body may divide the chamber into a compression sub-chamber and a rebound sub-chamber, the first surface opposite the rebound sub-chamber.

The damper assembly may include a spring urging the orifice disc toward the body.

The spring may include a main body spaced from the orifice disc along the axis and an arm, the arm extending radially outward from the main body and toward the orifice disc along the axis.

The orifice disc in the second flexed position may abut the first surface surrounding the passage.

In the present disclosure, and as further described herein, the body defining one or more passages is provided by the exemplary piston 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 a compression sub-chamber and a rebound sub-chamber that are on opposite sides of the piston. Such fluid movement may flex discs, e.g., check discs, blow off discs, spring discs, etc., attached to the piston. Flex of the discs attached to the piston controls an opening size of the passages of the piston, regulating fluid flow therethrough and providing variable and tunable resistance to the damper assembly. As an alternative to the piston, the body may 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 may provide fluid flow between the working chamber of the pressure tube and a reservoir chamber outside the pressure tube. The base may include the surfaces, features, passages, etc., as described for the piston herein. The various discs described herein may be attached to the base, e.g., as described for the discs attached to the piston, including their orientation, relative positions, etc. The base and the various discs may 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 may cause fluid to flow between the working chamber and the reservoir chamber via the passages of the base and may flex the discs attached to the base. Flex of the discs attached to the base controls an opening size of the passages of the base, regulating fluid flow therethrough and providing variable and tunable resistance to the damper assembly.

With reference to <FIG>, wherein like numerals indicate like parts throughout the several views, a vehicle <NUM> may include a plurality of damper assemblies <NUM>. Each damper assembly <NUM> includes a pressure tube <NUM> defining a chamber <NUM>. The damper assembly <NUM> includes a piston <NUM> slidable within the chamber <NUM> along an axis A1. The piston <NUM> includes a first surface <NUM>. The piston <NUM> includes a second surface <NUM> opposite and spaced from the first surface <NUM> along the axis A1. The piston <NUM> defines a first passage <NUM> extending from the first surface <NUM> to the second surface <NUM>. The damper assembly <NUM> includes an orifice disc <NUM>, <NUM> movable from an unflexed position to a first flexed position, and movable from the first flexed position to a second flexed position. The orifice disc <NUM>, <NUM> in the unflexed position is spaced from the piston <NUM>, i.e., from a respective one or the first surface <NUM> or the second surface <NUM>, radially outward and radially inward of the first passage <NUM>, as shown in <FIG> and <FIG>. The orifice disc <NUM>, <NUM> in the first flexed position is spaced from the piston <NUM> radially outward of the first passage <NUM> and abuts the piston <NUM> radially inward of the first passage <NUM>, e.g., as shown by the orifice disc <NUM> in <FIG>. The orifice disc <NUM>, <NUM> in the second flexed position abuts the first surface radially outward and radially inward of the first passage <NUM>, as shown in <FIG> and <FIG>. Movement of the orifice disc <NUM>, <NUM> from the unflexed position to the first flexed position, and from the first flexed position to the second flexed position, provides progressive resistance to movement of damper assembly <NUM> that varies with respect to a velocity and/or pressure of fluid in the pressure tube <NUM>. For example, the orifice disc <NUM>, <NUM> may move from the unflexed position to the first flexed position in response to relatively a lower velocity and/or pressure than a velocity and/or pressure required to move the orifice disc <NUM>, <NUM> from the first flexed position to the second flexed position.

The vehicle <NUM>, illustrated in <FIG>, may be any type of passenger or commercial vehicle such as a car, a truck, a sport utility vehicle, a crossover vehicle, a van, a minivan, a taxi, a bus, etc. The vehicle <NUM> includes a body <NUM> and a frame. The body <NUM> and frame may be of a unibody construction. In the unibody construction, the body <NUM>, e.g., rockers, serves as the vehicle frame, and the body <NUM> (including the rockers, pillars, roof rails, etc.) is unitary, i.e., a continuous one-piece unit. As another example, the body <NUM> and frame may have a body-on-frame construction (also referred to as a cab-on-frame construction). In other words, the body <NUM> and frame are separate components, i.e., are modular, and the body <NUM> is supported on and affixed to the frame. Alternatively, the body <NUM> and frame may have any suitable construction. The body <NUM> and/or the frame may be formed of any suitable material, for example, steel, aluminum, etc. The vehicle <NUM> includes wheels <NUM> that control motion of the vehicle <NUM> relative to ground supporting the vehicle <NUM>, e.g., acceleration, declaration, turning, etc. Vertical movement of the wheels <NUM> relative to the body <NUM> affects an amount of traction between the wheels <NUM> and the ground and an amount of vertical acceleration experienced by occupants of the vehicle <NUM> when the vehicle <NUM> travels over bumps and the like, e.g., the ride feel experienced by the occupants.

The damper assemblies <NUM> are typically used in conjunction with automotive suspension systems or other suspension systems to control movement of the wheels <NUM> of the vehicle <NUM> relative to the body <NUM> of the vehicle <NUM>. In order to control movement, dampers are generally connected between the sprung (body <NUM>) and the unsprung (suspension/drivetrain) masses of the vehicle <NUM>.

With reference to <FIG>, the damper assembly <NUM> is movable from a compressed position to an extended position, and vice versa. A distance between ends <NUM> of the damper assembly <NUM> is less in the compressed position than in the extended position. Springs or the like may urge the damper assemblies <NUM> toward the extended position. Force applied to wheels <NUM> of the vehicle <NUM>, e.g., from bumps, potholes, etc., may urge to damper assemblies <NUM> toward the compressed position.

Each damper assembly <NUM> controls movement of respective wheels <NUM> by limiting fluid flow into, out of, and/or between working chambers of the dampener, e.g., between a compression sub-chamber <NUM> and a rebound sub-chamber <NUM>. Fluid movement is caused by a movement of the piston <NUM> within the pressure tube <NUM> of the damper assembly <NUM>, e.g., when the damper assembly <NUM> is moved toward the compressed position or the extended position.

The damper assembly <NUM> defines the axis A1. The axis A1 extends between the ends <NUM> of the damper assembly <NUM>. The damper assembly <NUM> may be elongated along the axis A1. The terms "axially," "radially," and "circumferentially" used herein are relative to the axis A1 defined by the damper assembly <NUM>.

The pressure tube <NUM> defines the chamber <NUM>. For example, the pressure tube <NUM> may be hollow and tubular, enclosing the chamber <NUM> therein. The chamber <NUM> is filled with fluid, e.g., an incompressible hydraulic fluid. Movement of the damper assembly <NUM>, e.g., to the extended or compressed position, may increase and/or decrease fluid pressure in the pressure tube <NUM>, e.g., in the compression sub-chamber <NUM> and the rebound sub-chamber <NUM>. The pressure tube <NUM> may be elongated along the axis A1 of the damper assembly <NUM>. The pressure tube <NUM> may be metal, or any suitable material.

The damper assembly <NUM> includes a rod <NUM> extending away from, and movable relative to, the pressure tube <NUM>. The rod <NUM> may be elongated along the axis A1 of the damper assembly <NUM>. The rod <NUM> is moved relative to the pressure tube <NUM> when the damper assembly <NUM> is moved toward the compressed position or the extended position. The rod <NUM> may extend from within the chamber <NUM> of the pressure tube <NUM> to outside the chamber <NUM>, e.g., from the piston <NUM> and through the rebound sub-chamber <NUM>.

The piston <NUM> divides the chamber <NUM> of the pressure tube <NUM> into the compression sub-chamber <NUM> and the rebound sub-chamber <NUM>, i.e., with the compression sub-chamber <NUM> on one side of the piston <NUM> and the rebound sub-chamber <NUM> on the opposite side of the piston <NUM> along the axis A1. An outer circumferential surface <NUM> of the piston <NUM> may be sealed to an inner surface of the pressure tube <NUM>. The piston <NUM> is slidable within the chamber <NUM> of the pressure tube <NUM> along the axis A1. Sliding the piston <NUM> along the axis A1 varies volumes of the compression sub-chamber <NUM> and the rebound sub-chamber <NUM>. For example, a volume of the compression sub-chamber <NUM> may decrease, and a volume of the rebound sub-chamber <NUM> may increase, when the damper assembly <NUM> is moved toward the compressed position. As another example, the volume of the rebound sub-chamber <NUM> may decrease, and the volume of the compression sub-chamber <NUM> may increase, when the damper assembly <NUM> is moved toward the compressed position. The piston <NUM> is connected to the rod <NUM>, i.e., such that the piston <NUM> and the rod <NUM> move generally in unison. The piston <NUM> may be fixed to the rod <NUM>, e.g., via a fastener <NUM> and/or other suitable structure such as a weld, friction fit, etc. The piston <NUM> may be metal, plastic, or any suitable material.

With reference to <FIG>, the first surface <NUM> and the second surface <NUM> of the piston <NUM> extend generally radially outward from the rod <NUM> to the outer circumferential surface <NUM> of the piston <NUM>. The first surface <NUM> may be opposite and spaced from the second surface <NUM> along the axis A1. The second surface <NUM> may be opposite the compression sub-chamber <NUM> relative to the piston <NUM> and along the axis A1. The first surface <NUM> is opposite the rebound sub-chamber <NUM> relative to the piston <NUM> and along the axis A1. For example, the first surface <NUM> may face the rebound sub-chamber <NUM> with the second surface <NUM> between the first surface <NUM> and the rebound sub-chamber <NUM>. As another example, the second surface <NUM> may face the compression sub-chamber <NUM> with the first surface <NUM> between the second surface <NUM> and the compression sub-chamber <NUM>.

The first surface <NUM> and/or the second surface <NUM> may each include a first portion <NUM>, <NUM> that extends transversely relative to the axis A1. For example, the first portion <NUM>, <NUM> of the respective first surface <NUM> or the second surface <NUM> may extend away from the rod <NUM> and perpendicular relative to the axis A1. The axis A1 may extend normally relative to the first portion <NUM>, <NUM> of the first surface <NUM> and/or the second surface <NUM>.

The first surface <NUM> and/or the second surface <NUM> may each include a second portion <NUM>, <NUM>. The second portion <NUM>, <NUM> extends transversely relative to the axis A1 and the respective first portion <NUM>, <NUM>. A slope of the first portion <NUM>, <NUM> is different than a slope of the second portion <NUM>, <NUM> relative to the axis A1. For example, the second portion <NUM> of the first surface <NUM> may extend transversely relative to the first portion <NUM> of the first surface <NUM>, and the second portion <NUM> of the second surface <NUM> may extend transversely relative to the first portion <NUM> of the second surface <NUM>. The second portion <NUM>, <NUM> extends away from the respective first portion <NUM>, <NUM> and toward the first surface <NUM> or the second surface <NUM> that is opposite the respective second portion <NUM>, <NUM>. For example, the second portion <NUM> of the first surface <NUM> may extend from the first portion <NUM> toward the second surface <NUM> relative to the axis A1. The second portion <NUM> of the second surface <NUM> may extend from the first portion <NUM> toward the first surface <NUM> relative to the axis A1. The second portion <NUM>, <NUM> is illustrated a linear in cross section extending from the first portion <NUM>, <NUM>. Alternatively, second portion <NUM>, <NUM> may include a radius, e.g., the second portion <NUM>, <NUM> of the first surface <NUM> or the second surface <NUM> may curve toward the opposite the respective second portion <NUM>, <NUM>. The first portion <NUM>, <NUM> is radially inward of the respective second portion <NUM>, <NUM>. For example, the first portion <NUM> of the first surface <NUM> may be radially between the rod <NUM> and the second portion <NUM> of the first surface <NUM>. The first portion <NUM> of the second surface <NUM> may be radially between the rod <NUM> and the second portion <NUM> of the second surface <NUM>. A distance between the first surface <NUM> and the second surface <NUM> along the axis A1 may be less at the second portions <NUM>, <NUM> than at the first portions <NUM>, <NUM>.

A bend <NUM>, <NUM> may be defined between the first portion <NUM>, <NUM> and the second portion <NUM>, <NUM> of the first surface <NUM> and/or the second surface <NUM>. The bend <NUM>, <NUM> is defined by the difference in slope of the first portion <NUM>, <NUM> and the second portion <NUM>, <NUM>. For example, the bend <NUM> of the first surface <NUM> may be defined by the difference in slope of the first portion <NUM> and the second portion <NUM> of the first surface <NUM>. As another example, the bend <NUM> of the second surface <NUM> may be defined by the difference in slope of the first portion <NUM> and the second portion <NUM> of the second surface <NUM>. The bend <NUM>, <NUM> is radially between the first portion <NUM>, <NUM> and the second portion <NUM>, <NUM> of the respective first surface <NUM> and/or second surface <NUM>. The distance between the second portion <NUM> of the first surface <NUM> and the second portion <NUM> of the second surface <NUM> along the axis A1 may be greater at the bends <NUM>, <NUM> than at the outer circumferential surface <NUM> of the piston <NUM>. The bends <NUM>, <NUM> are shown as being generally the same difference in slope. Alternately, the bends <NUM>, <NUM> may be defined by different slopes. For example, the slope of the bend <NUM> one side of the first surface <NUM> may be different than the slope of the bend <NUM> circumferentially opposite (e.g., spaced <NUM> degrees about the axis A1) such bend <NUM>.

The piston <NUM> defines one or more passages, e.g., one or more first passages <NUM>, second passages <NUM>, and third passages <NUM>. The passages <NUM>, <NUM>, <NUM> extend from the first surface <NUM> of the piston <NUM> to the second surface <NUM> of the piston <NUM>. The passages <NUM>, <NUM>, <NUM> may be spaced circumferentially about the axis A1. The passages <NUM>, <NUM>, <NUM> provide fluid communication between the compression sub-chamber <NUM> and the rebound sub-chamber <NUM> of the pressure tube <NUM>, i.e., such that fluid may flow from the compression sub-chamber <NUM> to the rebound sub-chamber <NUM> in a first direction D1, or vice versa in a second direction D2 opposite the first direction D1. The first direction D1 is shown in the drawings as being from the second surface <NUM> to the first surface <NUM> however, the first direction D1 may be from the first surface <NUM> to the second surface <NUM>.

The first passage <NUM> may be at the second portion <NUM> of the first surface <NUM> and/or the second portion <NUM> of the second surface <NUM>. For example, the first passage <NUM> may extend from an open end at the second portion <NUM> of the first surface <NUM> to an open end at the second portion <NUM> of the second surface <NUM>. The open ends may be surrounded by the respective second portions <NUM>, <NUM>. The first surface <NUM> radially inward of the first passage <NUM> may be spaced along the axis A1 from the first surface <NUM> radially outward of the first passage <NUM>. The second surface <NUM> radially inward of the first passage <NUM> may be spaced along the axis A1 from the second surface <NUM> radially outward of the first passage <NUM>. For example, a distance along the axis A1 between the first surface <NUM> and the second surface <NUM> radially inward of the first passage <NUM> may be greater than a distance along the axis A1 between the first surface <NUM> and the second surface <NUM> radially outward of the first passage <NUM>. The bends <NUM>, <NUM> may be radially inward of the first passage <NUM>, e.g., the bends <NUM>, <NUM> may be between the first passage <NUM> and the rod <NUM> perpendicular to the axis A1. The bends <NUM>, <NUM> can also be at the first passages <NUM> or radially outwards (not shown).

The damper assembly <NUM> may include one or more fulcrum discs <NUM>, <NUM>, e.g., one fulcrum disc <NUM> at the first surface <NUM> and/or one fulcrum disc <NUM> at the second surface <NUM>. The fulcrum discs <NUM>, <NUM> provide fulcrum points for the orifice discs <NUM>, <NUM> and check discs <NUM>, <NUM>. For example, one of the fulcrum discs <NUM> may abut the first surface <NUM>. Another of the fulcrum discs <NUM> may abut the second surface <NUM>. The fulcrum discs <NUM>, <NUM> may extend radially outward from the rod <NUM> to outer edges <NUM>, <NUM>. The fulcrum discs <NUM>, <NUM> may be radially inward of the passages <NUM>, <NUM>, <NUM>. For example, the outer edge outer edges <NUM>, <NUM> of the fulcrum discs <NUM>, <NUM> may be radially inward of the bends <NUM>, <NUM>.

The damper assembly <NUM> may include one or more check discs <NUM>, <NUM>, e.g., a check disc <NUM> at the first surface <NUM> and a check disc <NUM> at the second surface <NUM>. The check discs <NUM>, <NUM> increase a resistance to movement in response to fluid flow past the respective check disc <NUM>, <NUM> and/or a difference in fluid pressure on one side of the check disc <NUM>, <NUM> relative to an opposite side. The fluid flow and/or difference in fluid pressure may translate or flex the check disc <NUM>, <NUM> to decease a size of an opening <NUM>, <NUM> (illustrated in <FIG>, <FIG>, <FIG>, <FIG>, and <FIG>) through which fluid may flow and thereby increase resistance to movement. The check discs <NUM>, <NUM> may be supported by the piston <NUM> and/or the rod <NUM>, e.g., via a center opening of each of the check discs <NUM>, <NUM>.

The check discs <NUM>, <NUM> may be movable from an unflexed position illustrated in <FIG> and <FIG> to a first flexed position illustrated in <FIG> (showing the check disc <NUM> in the first flexed position). The check discs <NUM>, <NUM> may flex at the respective fulcrum disc <NUM>, <NUM> when moving from the unflexed position to the first flexed position. The respective opening <NUM>, <NUM> may be smaller in the first flexed position than in the unflexed position. The check discs <NUM>, <NUM> may further be movable from the first flexed position to a second flexed position illustrated in <FIG> and <FIG>. The check discs <NUM>, <NUM> may flex at the respective bend <NUM>, <NUM> when moving from the first flexed position to the second flexed position. The respective opening <NUM>, <NUM> may be smaller in the second flexed position than in the first flexed position.

Returning to <FIG>, the check discs <NUM>, <NUM> may include extensions <NUM>, <NUM> that extend radially outward from a base ring <NUM>, <NUM> of the respective check disc <NUM>, <NUM>. The extensions <NUM>, <NUM> may be opposite each other, e.g., spaced from each other at generally <NUM> degrees around the axis A1. The check discs <NUM>, <NUM> may be bow-tie shaped. For example, a width of the extensions <NUM>, <NUM> may increase along the extensions <NUM>, <NUM>, e.g., such that the extensions <NUM>, <NUM> get wider as the extensions <NUM>, <NUM> extend away from the respective base ring <NUM>, <NUM>. Although illustrated as each having two extensions <NUM>, <NUM>, the check discs <NUM>, <NUM> may each include only one, or more than two, extensions <NUM>, <NUM>. The extensions <NUM>, <NUM> may cover the first passages <NUM>. For example, the extensions <NUM>, <NUM> may be circumferentially aligned with, and extend radially beyond, the first passages <NUM>.

The amount of flex and/or translation of the check disc <NUM>, <NUM> (and the associated decrease in size of the opening) may be proportional to a rate of fluid flow and/or a pressure differential between the compression sub-chamber <NUM> and the rebound sub-chamber <NUM> of the chamber <NUM>. For example, the greater the rate of fluid flow and/or difference in fluid pressure, the greater the amount of flex and/or translation of the check disc <NUM>, <NUM>. The proportionality of the amount of flex and/or translation of the check disc <NUM>, <NUM> to the rate of fluid flow and/or pressure differential may vary depending on whether the check disc <NUM>, <NUM> is moving between the unflexed position and the first flexed position or between the first flexed position and the second flexed position. For example, the amount of fluid flow necessary to move from the unflexed position to the first flexed position is generally less than the amount of fluid flow necessary to move from the first flexed position to the second flexed position.

A threshold rate of fluid flow and/or difference in fluid pressure may be required to flex and/or translate the check discs <NUM>, <NUM>. The check discs <NUM>, <NUM> may not increase resistance to movement until the threshold rate of fluid flow and/or difference in fluid pressure is achieved. The threshold rate of fluid flow and/or difference in fluid pressure may be determined based on desired response characteristics of the damper assembly <NUM>. The check discs <NUM>, <NUM> may be designed, e.g., via geometry such as thickness, material type, etc., to flex at the threshold rate of fluid flow and/or difference in fluid pressure. For example, increasing a thickness of the check discs <NUM>, <NUM> and/or selecting a stiffer material for the check discs <NUM>, <NUM> may increase the threshold rate of fluid flow and/or difference in fluid pressure required to decrease the size of the openings <NUM>, <NUM>. Decreasing the thickness of the check discs <NUM>, <NUM> and/or selecting a more flexible material for the check discs <NUM>, <NUM> may decrease the threshold rate of fluid flow and/or difference in fluid pressure required to decrease the size of the openings <NUM>, <NUM>.

The check disc <NUM> at the first surface <NUM> selectively restricts fluid flow through the first passages <NUM> in the second direction D2, i.e., depending on a direction and an amount of fluid pressure and/or speed of fluid flow applied to the check disc <NUM>. The check disc <NUM> at the first surface <NUM> selectively permits fluid through the first passages <NUM> by controlling a size of the opening <NUM> between the check disc <NUM> and the first surface <NUM> of the piston <NUM>. The check disc <NUM> at the second surface <NUM> selectively restricts fluid flow through the first passages <NUM> in the first direction D1 by controlling a size of the opening <NUM> between the check disc <NUM> and the second surface <NUM> of the piston <NUM>.

When the damper assembly <NUM> is moved toward the extended position the volume of the compression sub-chamber <NUM> is increased and the volume of the rebound sub-chamber <NUM> is decreased, thereby creating a pressure differential where fluid pressure is greater in the rebound sub-chamber <NUM> than in the compression sub-chamber <NUM>. Such pressure differential and/or fluid flow caused by such pressure differential may move the check disc <NUM> at the first surface <NUM> toward the piston <NUM>, decreasing the size of the opening <NUM> therebetween through which fluid may flow and increasing resistance to motion provided the damper assembly <NUM>.

When the damper assembly <NUM> is moved toward the compressed position the volume of the compression sub-chamber <NUM> is reduced and the volume of the rebound sub-chamber <NUM> is increased, thereby creating a pressure differential where fluid pressure is greater in the compression sub-chamber <NUM> than in the rebound sub-chamber <NUM>. Such pressure differential, and/or fluid flow caused by such pressure differential, may move the check disc <NUM> at the second surface <NUM> toward the piston <NUM>, decreasing the size of the opening <NUM> therebetween through which fluid may flow and increasing resistance to motion provided the damper assembly <NUM>.

The damper assembly <NUM> may include one or more orifice discs <NUM>, <NUM>, e.g., one orifice disc <NUM>, at the first surface <NUM> and/or one orifice disc <NUM>, <NUM> at the second surface <NUM>. The orifice discs <NUM>, <NUM> may be supported by the rod <NUM> and/or the piston <NUM>, e.g., via a center opening of the respective orifice disc <NUM>, <NUM>. The orifice disc <NUM>, <NUM> may be between the piston <NUM> and the respective check disc <NUM>, <NUM>, e.g., along the axis A1. One side of the orifice disc <NUM>, <NUM> may abut the respective fulcrum discs <NUM>, <NUM>, e.g., opposite the piston <NUM> relative to the axis A1. The fulcrum disc <NUM>, <NUM> may be between the piston <NUM> and the respective orifice disc <NUM>, <NUM> along the axis A1.

The orifice discs <NUM>, <NUM> may include extensions <NUM>, <NUM> that extend radially outward from a base ring <NUM>, <NUM> of the respective orifice disc <NUM>, <NUM>. The extensions <NUM>, <NUM> may be opposite each other, e.g., spaced from each other at generally <NUM> degrees around the axis A1. An outer edge of the base ring <NUM>, <NUM> may be aligned with the outer edge <NUM>, <NUM> of the respective fulcrum disc <NUM>, <NUM>. For example, the outer edge of the base ring <NUM>, <NUM> and the outer edge of <NUM>, <NUM> the respective fulcrum disc <NUM>, <NUM> may be generally equally spaced from the axis A1. The orifice discs <NUM>, <NUM> may be bow-tie shaped. For example, a width of the extensions <NUM>, <NUM> may increase along the extensions <NUM>, <NUM>, e.g., such that the extensions <NUM>, <NUM> get wider as the extensions <NUM>, <NUM> extend away from the base ring <NUM>, <NUM>. The extensions <NUM>, <NUM> of the orifice discs <NUM>, <NUM> may be aligned with the extensions <NUM>, <NUM> of the check discs <NUM>, <NUM>, e.g., circumferentially relative to the axis A1. Although illustrated as each having two extensions <NUM>, <NUM>, the orifice discs <NUM>, <NUM> may each include only one, or more than two, extensions <NUM>, <NUM>. The extensions <NUM>, <NUM> may cover the first passages <NUM>. For example, the extensions <NUM>, <NUM> may be circumferentially aligned with, and extend radially beyond, the first passages <NUM>.

Each orifice disc <NUM>, <NUM> defines one or more orifices <NUM>, <NUM>. The orifices <NUM>, <NUM> permit fluid flow axially and/or radially relative to the axis A1 of the damper assembly <NUM>. Each orifice <NUM>, <NUM> may be open in a radial direction. For example, orifices <NUM>, <NUM> may extend radially inward from outer edges of the extensions <NUM>, <NUM> of the respective orifice disc <NUM>, <NUM>, e.g., such that fluid may flow radially into the orifices <NUM>, <NUM> at the outer edges. The orifices <NUM>, <NUM> of the orifice discs <NUM>, <NUM> may be at the first passage <NUM>, e.g., generally circumferentially aligned relative to, and generally radially equally spaced from, the open ends of the first passages <NUM>. The check disc <NUM>, <NUM> may cover the orifice <NUM>, <NUM>. For example, the extension of the check disc <NUM>, <NUM> may extend circumferentially and radially across the orifice <NUM>, <NUM>. The orifices <NUM>, <NUM> enable fluid flow through the first passage <NUM>, e.g., by maintaining minimum sizes to the openings <NUM>, <NUM> between the check discs <NUM>, <NUM> and piston <NUM> when the check discs <NUM>, <NUM> are in the second flexed position. For example, the minimum size of the opening may be equal to a radial flow area of the orifice <NUM>, <NUM>.

The orifice discs <NUM>, <NUM> are movable from the unflexed position to the first flexed position and movable from the first flexed position to the second flexed position, e.g., in response to fluid flow past the respective orifice disc <NUM>, <NUM> and as described for the check discs <NUM>, <NUM>. The orifice discs <NUM>, <NUM> may move concurrently with the check discs <NUM>, <NUM>. For example, movement of the check disc <NUM> at the second surface <NUM> from the unflexed position to the first flexed position may urge the orifice disc <NUM> at the second surface <NUM> from the unflexed position toward the first flexed position. As another example, movement of the check disc <NUM> at the first surface <NUM> from the first flexed position to the second flexed position may urge the orifice disc <NUM> at the first surface <NUM> from the first flexed position toward the second flexed position.

The orifice discs <NUM>, <NUM> in the unflexed positions are spaced from the respective first surface <NUM> or second surface <NUM> radially outward and radially inward of the first passage <NUM>. For example, the extensions <NUM> of the orifice disc <NUM> at the first surface <NUM> in the unflexed position may be spaced from the bend <NUM> and the second portion <NUM> of the first surface <NUM>. The extensions <NUM> of the orifice disc <NUM> at the second surface <NUM> in the unflexed position may be spaced from the bend <NUM> and the second portion <NUM> of the second surface <NUM>. The orifice disc <NUM>, <NUM> in the unflexed position may be planar and extend generally perpendicular relative to the axis A1.

The orifice discs <NUM>, <NUM> in the first flexed position are spaced from the respective first surface <NUM> or second surface <NUM> radially outward of the first passage <NUM> and abut the respective first surface <NUM> or second surface <NUM> radially inward of the first passage <NUM>. For example, the extensions <NUM> of the orifice disc <NUM> at the first surface <NUM> in the first flexed position may abut the bend <NUM> and be spaced from the second portion <NUM> of the first surface <NUM>. The extensions <NUM> of the orifice disc <NUM> at the second surface <NUM> in the first flexed position may abut the bend <NUM> and be spaced from the second portion <NUM> of the second surface <NUM>. The orifice disc <NUM>, <NUM> in the first flexed position may include a first bend <NUM>, <NUM>, e.g., at the fulcrum disc <NUM>, <NUM> (shown in <FIG>, <FIG>, <FIG>, and <FIG>).

The orifice disc <NUM>, <NUM> in the second flexed position abuts the respective first surface <NUM> or second surface <NUM> radially outward and radially inward of the first passage <NUM>. For example, the extensions <NUM> of the orifice disc <NUM> at the first surface <NUM> in the second flexed position may abut the bend <NUM> and the second portion <NUM> outward of the first passage <NUM> at the first surface <NUM>. The extensions <NUM> of the orifice disc <NUM> at the second surface <NUM> in the second position may abut the bend <NUM> and be spaced from the second portion <NUM> outward of the first passage <NUM> at the second surface <NUM>. The orifice disc <NUM>, <NUM> in the second flexed position may include a second bend <NUM>, <NUM>, e.g., at the bend <NUM>, <NUM> of the respective first surface <NUM> or second surface <NUM>. The orifice disc <NUM>, <NUM> in the second flexed position abuts the respective first surface <NUM> or second surface <NUM> surrounding the first passage <NUM>, with the orifice <NUM>, <NUM> in fluid communication with the first passage <NUM>. Abutting the first surface <NUM> or second surface <NUM> surrounding the first passage <NUM> with the orifice <NUM>, <NUM> in fluid communication with the first passage <NUM> inhibits fluid flow into the first passage <NUM> except via the orifice <NUM>, <NUM>.

The damper assembly <NUM> may include one or more springs <NUM>, <NUM>, e.g., a spring <NUM> at the first surface <NUM> and a spring <NUM> at the second surface <NUM>. The springs <NUM>, <NUM> urge the check discs <NUM>, <NUM>, the orifice discs <NUM>, <NUM>, and the fulcrum discs <NUM>, <NUM> toward the piston <NUM>. For example, the spring <NUM> at the first surface <NUM> may compress the check disc <NUM>, the orifice disc <NUM>, and the fulcrum disc <NUM> against the first surface <NUM>. As another example, the spring <NUM> at the second surface <NUM> may compress the check disc <NUM>, the orifice disc <NUM>, and the fulcrum disc <NUM> against the second surface <NUM>.

Each of the springs <NUM>, <NUM> may include a main body <NUM>, <NUM> spaced from the orifice disc <NUM>, <NUM> along the axis A1. Each of the springs <NUM>, <NUM> may include a plurality of arms <NUM>, <NUM> extending circumferentially and radially outward from the main body <NUM>, <NUM> and toward the respective orifice disc <NUM>, <NUM> along the axis A1. The springs <NUM>, <NUM> may be supported by the rod <NUM>, e.g., via a center opening of the main body <NUM>, <NUM>. The springs <NUM>, <NUM> are made from an elastically deformable material, e.g., spring steel, plastic having suitable elastic properties, etc. The arms <NUM>, <NUM> of the springs <NUM>, <NUM> may abut the check discs <NUM>, <NUM>. For example, arms <NUM> of the spring <NUM> at the first surface <NUM> may abut the check disc <NUM> at the first surface <NUM> opposite the orifice disc <NUM> relative to the axis A1. As another example, arms <NUM> of the spring <NUM> at the second surface <NUM> may abut the check disc <NUM> at the second surface <NUM> surface opposite the orifice disc <NUM> relative to the axis A1.

The damper assembly <NUM> may include one or more blow off discs <NUM>, <NUM>, e.g., a blow off disc <NUM> at the first surface <NUM> and/or a blow off disc <NUM> at the second surface <NUM>. The blow off discs <NUM>, <NUM> may be supported by the rod <NUM>. For example, each blow off disc <NUM>, <NUM> may include a center opening and the rod <NUM> may be in the center openings. The blow off discs <NUM>, <NUM> may be axially outward of the springs <NUM>, <NUM> relative to the piston <NUM>. For example, the blow off disc <NUM> at the first surface <NUM> may abut the spring <NUM> opposite the first surface <NUM>. As another example, the blow off disc <NUM> at the second surface <NUM> may abut the spring <NUM> opposite the second surface <NUM>.

The blow off discs <NUM>, <NUM> decrease a resistance to movement in response to fluid flow past the blow off disc <NUM>, <NUM> and/or a difference in fluid pressure on one side of the blow off disc <NUM>, <NUM> relative to an opposite side. The fluid flow and/or difference in fluid pressure may translate or flex the blow off disc <NUM>, <NUM> to create, and/or increase a size of, an opening <NUM>, <NUM> (illustrated in <FIG> and <FIG>) through which fluid may flow. Increasing the size of the openings <NUM>, <NUM> decreases resistance to movement by permitting a greater amount of fluid to flow from one sub-chamber <NUM>, <NUM> to the other sub-chamber <NUM>, <NUM>. The amount of flex and/or translation of the blow off discs <NUM>, <NUM> and the resulting increase in size of the openings <NUM>, <NUM> may be proportional to a rate of fluid flow and/or the pressure difference between the compression sub-chamber <NUM> and the rebound sub-chamber <NUM>. For example, the greater the rate of fluid flow and/or difference in fluid pressure, the greater the amount of flex and/or translation of the blow off discs <NUM>, <NUM> away the piston <NUM>, providing a greater magnitude of increase of the size the openings <NUM>, <NUM> therebetween. A threshold rate of fluid flow and/or difference in fluid pressure may be required to flex and/or translate the blow off discs <NUM>, <NUM>. The blow off discs <NUM>, <NUM> may not decrease resistance to movement until the threshold rate of fluid flow and/or difference in fluid pressure is achieved.

Each blow off disc <NUM>, <NUM> may define one or more openings <NUM>, <NUM>. The openings <NUM>, <NUM> permit fluid flow from one side of the respective blow off disc <NUM>, <NUM> to another side of the respective blow off disc <NUM>, <NUM>. The openings <NUM>, <NUM> may decrease a stiffness of the blow off disc <NUM>, <NUM>. The openings <NUM>, <NUM> may be arranged about the axis A1. The openings <NUM>, <NUM> of each blow off disc <NUM>, <NUM> may circumferentially overlap, i.e., two or more openings <NUM>, <NUM> may be along a common radius extending from the axis A1. Such openings <NUM>, <NUM> may be spaced from each other along the radius.

The blow off disc <NUM> at the first surface <NUM> may be spaced from the first surface <NUM> at the second passages <NUM>. Spacing the blow off disc <NUM> from the first surface <NUM> at the second passages <NUM> permits fluid to freely flow into and out of the second passages <NUM>, e.g., without inhibition of such flow by the blow off disc <NUM> at the first surface <NUM>.

The blow off disc <NUM> at the first surface <NUM> selectively permits fluid flow out of the third passages <NUM>, i.e., depending on an amount and direction of fluid pressure applied to the blow off disc <NUM>. For example, the blow off disc <NUM> at the first surface <NUM> may selectively permit fluid flow through the third passages <NUM> in the second direction D2. The blow off disc <NUM> selectively permits fluid flow by controlling the size of the opening <NUM> between the blow off disc <NUM> and the first surface <NUM> of the piston <NUM> at the third passages <NUM>.

When the damper assembly <NUM> is in a neutral state, i.e., not moving toward the extended position or the compressed position, the blow off disc <NUM> at the first surface <NUM> covers the third passages <NUM> and restricts or inhibits fluid flow into, and out of, the third passages <NUM>. The blow off disc <NUM> in the neutral state may abut the first surface <NUM> of the piston <NUM> at the third passages <NUM>, e.g., surrounding an open end of the second passage <NUM>.

When the damper assembly <NUM> is moved toward the compressed position the blow off disc <NUM> at the first surface <NUM> may be moved away from the piston <NUM> by the pressure differential and/or fluid flow resulting from such movement. Moving the blow off disc <NUM> away from the piston <NUM> creates the opening <NUM> between first surface <NUM> of the piston <NUM> and the blow off disc <NUM>. Fluid may flow out of the third passages <NUM> through the opening <NUM> to the rebound sub-chamber <NUM>.

When the damper assembly <NUM> is moved toward the extended position the blow off disc <NUM> at the first surface <NUM> may be urged toward the piston <NUM>, not creating or enlarging the opening <NUM> between the first surface <NUM> of the piston <NUM> and the blow off disc <NUM>.

The blow off disc <NUM> at the second surface <NUM> may be spaced from the second surface <NUM> at the third passages <NUM>. Spacing the blow off disc <NUM> from the second surface <NUM> at the third passages <NUM> permits fluid to freely flow into and out of the second passages <NUM>, e.g., without inhibition of such flow by the blow off disc <NUM> at the second surface <NUM>.

The blow off disc <NUM> at the second surface <NUM> selectively permits fluid flow out of the second passages <NUM> of the piston <NUM>, i.e., depending on an amount and direction of fluid pressure applied to the blow off disc <NUM>. For example, the blow off disc <NUM> at the second surface <NUM> may selectively permit fluid flow through the second passages <NUM> in the first direction D1. The blow off disc <NUM> selectively permits fluid flow by controlling the size of the opening <NUM> between the blow off disc <NUM> and the second surface <NUM> of the piston <NUM>.

When the damper assembly <NUM> is in the neutral state the blow off disc <NUM> at the second surface <NUM> covers the second passages <NUM> at the second surface <NUM> and restricts or inhibits fluid flow into, and out of, the second passages <NUM>. The blow off disc <NUM> in the neutral state may abut the second surface <NUM> of the piston <NUM> at the second passages <NUM>, e.g., surrounding open ends of the second passages <NUM>.

When the damper assembly <NUM> is moved toward the extended position and pressure is greater in the rebound sub-chamber <NUM> than in the compression sub-chamber <NUM>, the blow off disc <NUM> at the second surface <NUM> may be moved away from the piston <NUM> and create the opening <NUM> between the second surface <NUM> and the blow off disc <NUM>. Fluid may flow out of the second passages <NUM> through the opening <NUM> to the compression sub-chamber <NUM>.

When the damper assembly <NUM> is moved toward the compressed position and fluid pressure is greater in the compression sub-chamber <NUM> in the rebound sub-chamber <NUM> the blow off disc <NUM> at the second surface <NUM> may be urged toward the piston <NUM>, not creating or enlarging the opening <NUM> between the piston <NUM> and the blow off disc <NUM>.

The damper assembly <NUM> may include one or more spring discs 140a-140d, 142a-142d, e.g., one or more spring discs 140a-140d at the first surface <NUM> and/or one or more spring discs 142a-142d at the second surface <NUM>. The spring discs 140a-140d, 142a-142d may be supported by the rod <NUM>. For example, the rod <NUM> may extend through center openings of the spring discs 140a-140d, 142a-142d. The spring discs 140a-140d, 142a-142d are elastically deformable. For example, force applied to an outer edge of the spring discs 140a-140d, 142a-142d may cause the spring discs 140a-140d, 142a-142d to flex such that the outer edge is moved axially relative the respective center opening of the spring discs 140a-140d, 142a-142d. The spring discs 140a-140d, 142a-142d are made from an elastically deformable material, e.g., spring steel, plastic having suitable elastic properties, etc..

The spring discs 140a-140d at the first surface <NUM> urge the blow off disc <NUM> at the first surface <NUM> toward the piston <NUM>, i.e., the spring discs 140a-140d increase an amount of force required to flex the blow off disc <NUM> away from the first surface <NUM>. The spring discs 142a-142d at the second surface <NUM> urge the blow off disc <NUM> at the second surface <NUM> toward the piston <NUM>, i.e., the spring discs 142a-142d increase an amount of force required to flex the blow off disc <NUM> away from the second surface <NUM>.

The spring discs 140a-140d, 142a-142d may progressively decrease in size as a function of the distance from the piston <NUM> along the axis A1. For example, the spring disc 140a, 142a closest to the piston <NUM> may have a larger outer diameter than an outer diameter of the spring disc 140b, 142b adjacent such spring disc 140a, 142a, and so on. The spring disc 140d, 142d farthest from the piston <NUM> may have a diameter smaller that diameters of the other spring discs 140a-140c, 142a-142c. As another example, the spring discs 140a-140d, 142a-142d may be configured similar to a leaf spring.

The spring discs 140d, 142d closest the piston <NUM> may abut the respective blow off discs <NUM>, <NUM> proximate the rod <NUM>. The spring discs 140a, 142a closest the piston <NUM> may be spaced from the blow off discs <NUM>, <NUM> at outer edges of the blow off discs <NUM>, <NUM>. For example, a ring <NUM> at the first surface <NUM> may be between the spring disc 140a and the blow off disc <NUM> at the first surface <NUM> along the axis A1. As another example, a ring <NUM> at the second surface <NUM> may be between the spring disc 142a and the blow off disc <NUM> at the second surface <NUM> along the axis A1. The rings <NUM>, <NUM> may be circular or any suitable shape. The rings <NUM>, <NUM> may be metal, plastic, or any suitable material. The rings <NUM>, <NUM> provide internal preload forces to the spring discs 140a-140d, 142a-142d. The rings <NUM>, <NUM> may be radially outward of the openings <NUM>, <NUM> of the blow off discs <NUM>, <NUM>.

Each damper assembly <NUM> may include a pair of second fulcrum discs <NUM>, <NUM>. The second fulcrum discs <NUM>, <NUM> provide fulcrum points for the spring discs 140a-140d, 142a-142d. For example, one of the second fulcrum discs <NUM> may abut the smallest spring disc 140d at the first surface <NUM> opposite the adjacent larger spring disc 140c. Such second fulcrum disc <NUM> may have a smaller outer diameter than the abutting smallest spring disc 140d. As another example, the second fulcrum disc <NUM> at the second surface <NUM> may abut the smallest spring disc 142d at the second surface <NUM> opposite the adjacent larger spring disc 142c. Such second fulcrum disc <NUM> may have a smaller outer diameter than the smallest spring disc 142d at the second surface <NUM>.

Each damper assembly <NUM> may include a pair of preload spacers <NUM>, <NUM>. The preload spacers <NUM>, <NUM> protect the spring discs 140a-140d, 142a-142d. The preload spacers <NUM>, <NUM> sandwich the piston <NUM>, the discs, and other components of the damper assembly <NUM> supported by the rod <NUM>. A thickness of the preload spacers <NUM>, <NUM> may increase or decrease space available for the discs, the piston <NUM>, etc. For example, the preload spacer <NUM> at the first surface <NUM> may be axially outboard of the second fulcrum disc <NUM> at the first surface <NUM> and the preload spacer <NUM> at the second surface <NUM> may be axially outboard of the second fulcrum disc <NUM> at the second surface <NUM>. The fastener <NUM> may be fixed to the rod <NUM> axially outboard of the preload spacer <NUM> at the second surface <NUM>. The fastener <NUM> may be, for example, a threaded lock nut. The fastener <NUM> may confine the preload spacers <NUM>, <NUM>, the blow off discs <NUM>, <NUM>, the spring discs 140a-140d, 142a-142d, the piston <NUM>, etc., to a stack having a predetermined length.

With reference to <FIG>, a first fluid flow path FF1 defined by the damper assembly <NUM> is illustrated. The first fluid flow path FF1 is defined when the damper assembly <NUM> is moved toward the extended position. The first fluid flows path extends from the rebound sub-chamber <NUM> around the preload spacer <NUM>, the spring discs 140a-140d, and the blow off disc <NUM> to the opening <NUM> between the check disc <NUM> and the first surface <NUM> of the piston <NUM>. From the openings <NUM>, the first fluid flow path FF1 extends through first passages <NUM> and out the openings <NUM> between the check disc <NUM> and the second surface <NUM> to the compression sub-chamber <NUM>.

The first fluid flow path FF1 defines an area, e.g., perpendicular to the first fluid flow path FF1, through which fluid may flow. The defined area may be at narrowest portion of the respective first fluid flow path FF1. The defined area may include multiple areas. For example, the first fluid flow path FF1 may split into multiple sub-paths, e.g., with each sub-path extending through one of the first passages <NUM>. The sub-paths may 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 may be a combination of the areas of the sub-paths.

When the fluid flow rate and/or pressure differential between the compression sub-chamber <NUM> and the rebound sub-chamber <NUM> is less than a first threshold, e.g., bleed flow, the areas defined by the first fluid flow path FF1 provides resistance to movement of the piston <NUM> by limiting a rate at which fluid may flow from the rebound sub-chamber <NUM> to the compression sub-chamber <NUM>. Such resistance is illustrated in <FIG> by a section W of a curve C1. The check disc <NUM> at the first surface <NUM> may be in the unflexed position when the fluid flow rate and/or pressure differential is less than the first threshold.

With reference to <FIG>, the damper assembly <NUM> is illustrated as moved toward the extended position when the fluid flow rate and/or the pressure differential between the rebound sub-chamber <NUM> and the compression sub-chamber <NUM> are greater than the first threshold. When the fluid flow rate and/or the pressure differential are greater than the first threshold, the fluid flow along the first fluid flow path FF1 moves the check disc <NUM> towards the first surface <NUM> of the piston <NUM> to the first flexed position, e.g., into abutment with the bend <NUM>. Moving the check disc <NUM> toward the piston <NUM> decreases the size of the opening <NUM> between the check disc <NUM> and the first surface <NUM>. Resistance provided by decreasing the size of the opening <NUM> is illustrated in <FIG> by a section X of a curve C1.

With reference to <FIG>, the damper assembly <NUM> is illustrated as moved toward the extended position when the fluid flow rate and/or the pressure differential between the rebound sub-chamber <NUM> and the compression sub-chamber <NUM> are greater than a second threshold. The second threshold is greater than the first threshold. When the fluid flow rate and/or the pressure differential are greater than the second threshold, the fluid flow along the first fluid flow path FF1 further moves the check disc <NUM> towards the first surface <NUM> of the piston <NUM> to the second flexed position, e.g., into abutment with the second portion <NUM> of the first surface <NUM> surrounding the first passage <NUM>. Moving the check disc <NUM> to the second flexed position minimizes the size of the opening <NUM>, e.g., to be generally equal to the radial flow area of the orifice <NUM> of the orifice disc <NUM>. Decreasing and/or minimizing the size of the opening <NUM> decreases the defined area of the first fluid flow path FF1 and increases resistance to movement of the respective damper assembly <NUM> by reducing the rate at which fluid may flow from the rebound sub-chamber <NUM> to the compression sub-chamber <NUM>. Such resistance is illustrated in <FIG> by a section Y of the curve C1.

The second threshold may be such that a magnitude of the curve C1 reaches a predetermined amount of response force within a predetermined amount of time. The first threshold may be such to control a shape of the curve C1, e.g., a radius of curvature, between the section X and the section Y of the curve C1. The predetermined amounts may be based on empirical testing, e.g., to optimize vehicle <NUM> performance and/or occupant comfort.

With reference to <FIG>, a second fluid flow FF2 path defined by the damper assembly <NUM> is illustrated. The second fluid flow FF2 path is defined when the respective damper assembly <NUM> is moved toward the extended position and the fluid flow rate and/or the pressure differential between the compression sub-chamber <NUM> and the rebound sub-chamber <NUM> is greater than a third threshold. The third threshold may be greater than the first and second thresholds such that a slope and/or magnitude of the curve C1 does not exceed a predetermined amount. The predetermined amount may be based on empirical testing, e.g., to optimize vehicle <NUM> performance and/or occupant comfort.

When the fluid flow rate and/or pressure differential is above the third threshold the blow off disc <NUM> and the spring discs 142a-142d at the second surface <NUM> are urged away from the piston <NUM> and the opening <NUM> therebetween is created. The second fluid flow FF2 path extends from the rebound sub-chamber <NUM> to the compression sub-chamber <NUM> via the second passages <NUM> and the opening <NUM> between the second surface <NUM> of the piston <NUM> and the blow off disc <NUM>. The second fluid flow FF2 path defines an area through which fluid may flow. The defined area of the second fluid flow FF2 path may include multiple sub-areas.

The combined defined areas of the first fluid flow path FF1 and the second fluid flow FF2 path reduce resistance to movement of the respective damper assembly <NUM> (relative to the defined area of just the first fluid flow path FF1) by increasing a rate at which fluid may flow from the rebound sub-chamber <NUM> to the compression sub-chamber <NUM>. Such resistance is illustrated in <FIG> by a section Z of the curve C1.

With reference to <FIG>, a third fluid flow path FF3 and a fourth fluid flow path FF4 defined by the damper assemblies <NUM> are illustrated. The third and fourth fluid flow paths FF3, FF4 may be defined when the damper assembly <NUM> is moved toward the compressed position.

The third fluid flow path FF3 extends from the compression sub-chamber <NUM><NUM> to the rebound sub-chamber via the first passages <NUM> and the openings <NUM> between the check disc <NUM> and second surface <NUM> of the piston <NUM>. <FIG> illustrates the check disc <NUM> in the second flexed position when the fluid flow rate and/or the pressure differential between the compression sub-chamber <NUM> and the rebound sub-chamber <NUM> is above the second threshold.

The fourth fluid flow path extends from the compression sub-chamber <NUM> to the rebound sub-chamber <NUM> via the third passages <NUM> and the opening <NUM> between the blow off disc <NUM> and the second surface <NUM> of the piston <NUM>. The fourth fluid flow path may be defined when the damper assembly <NUM> is moved toward the compressed position and the fluid flow rate and/or the pressure differential between the compression sub-chamber <NUM> and the rebound sub-chamber <NUM> is above the third threshold.

With reference to <FIG>, the curve C1 and a curve C2 are shown. The curve C1 indicates response force provided by the damper assembly <NUM> moving toward the extended position at increased speeds. The curve C2 indicates response force provided by the damper moving toward the compressed position at increased speeds. The various components of the damper assembly <NUM> may be configured to control the curves C1, C2, i.e., to control an amount of responsive force provided by the damper assembly <NUM> at various speeds.

The curves C1, C2 may be increased or decreased in slope and/or in magnitude proximate arrows A and A', e.g., providing tuning for low speed movement of the damper assembly <NUM>. For example, increasing a steepness of the slope of the second portion <NUM> of the first surface <NUM>, increasing a thickness of the fulcrum disc <NUM>, increasing a stiffness of the check disc <NUM>, and/or increasing a size of the orifice <NUM> of the orifice disc <NUM> may decrease the slope and/or magnitude of the curve C1 proximate arrow A. Similarly increasing a steepness of the slope of the second portion <NUM> of the second surface <NUM>, increasing a thickness of the fulcrum disc <NUM>, increasing a stiffness of the check disc <NUM>, and/or increasing a size of the orifice <NUM> of the orifice disc <NUM> may decrease the slope and/or magnitude of the curve C2 proximate arrow A'. As another example, decreasing a steepness of the slope of the second portion <NUM> of the first surface <NUM>, decreasing a thickness of the fulcrum disc <NUM>, decreasing the stiffness of the check disc <NUM>, and/or decreasing the size of the orifice <NUM> of the orifice disc <NUM> may increase the slope and/or magnitude of the curve C1 proximate arrow A. Similarly decreasing a steepness of the slope of the second portion <NUM> of the second surface <NUM>, decreasing the thickness of the fulcrum disc, <NUM> decreasing the stiffness of the check disc <NUM>, and/or decreasing the size of the orifice <NUM> of the orifice disc <NUM> may increase the slope and/or magnitude of the curve C2 proximate arrow A'.

The curves C1, C2 may be increased or decreased in slope and/or in magnitude proximate arrows B and B'. For example, increasing a stiffness of the blow off disc <NUM> at the second surface <NUM> may increase the slope and/or magnitude of the curve C1 proximate arrow B. Similarly, increasing a stiffness of the blow off disc <NUM> at the first surface <NUM> may increase the slope and/or magnitude of the curve C2 proximate arrow B'.

The curves C1, C2 may be increased or decreased in slope and/or in magnitude proximate arrows C and C', e.g., providing tuning for mid speed movement of the damper assembly <NUM>. For example, decreasing a thickness of the rings <NUM>, <NUM> may decrease the slope and/or magnitude of the curve C1 proximate arrow C and arrow C'. As another example, increasing the thickness of the rings <NUM>, <NUM> may increase the slope and/or magnitude of the curve C1 proximate arrow C and arrow C'.

The curves C1, C2 may be increased or decreased in slope and/or in magnitude proximate arrows D and D'. For example, increasing a stiffness of the spring discs 142a-142d at the second surface <NUM> may increase the slope and/or magnitude of the curve C1 proximate arrow D. Similarly, increasing a stiffness of the spring discs 140a-140d at the first surface <NUM> may increase the slope and/or magnitude of the curve C2 proximate arrow D'. As another example, decreasing the stiffness of the spring discs 142a-142d at the second surface <NUM> may decrease the slope and/or magnitude of the curve C1 proximate arrow D. Similarly, decreasing the thickness of the spring discs 140a-140d at the first surface <NUM> may decrease the slope and/or magnitude of the curve C2 proximate arrow D'.

Although the curves C1, C2 proximate the various arrows A, A', B, B', C, C', D, D' are described individually, the curves C1, C2 may be controlled based on a cumulative effect of the configuration of the various components. For example, configuring the damper assembly <NUM><NUM> to control the curves C1, C2 proximate arrows A, A', may also change the curves C1, C2, proximate the other arrows B, B', C, C', D, D'.

The adjectives "first," "second," and "third" are used as identifiers and are not intended to indicate significance or order.

Claim 1:
A damper assembly (<NUM>), comprising:
a pressure tube (<NUM>) defining a chamber (<NUM>);
a body (<NUM>) supported by the pressure tube (<NUM>), the body (<NUM>) having a first surface (<NUM>) and a second surface (<NUM>) opposite and spaced from the first surface (<NUM>) along an axis (A1), the body (<NUM>) defining a passage (<NUM>) extending from the first surface (<NUM>) to the second surface (<NUM>); and
an orifice disc (<NUM>, <NUM>) movable from an unflexed position to a first flexed position and movable from the first flexed position to a second flexed position;
the orifice disc (<NUM>, <NUM>) in the unflexed position is spaced from the first surface (<NUM>) radially outward and radially inward of the passage (<NUM>);
the orifice disc (<NUM>, <NUM>) in the first flexed position is spaced from the first surface (<NUM>) radially outward of the passage (<NUM>) and abuts the first surface (<NUM>) radially inward of the passage (<NUM>);
the orifice disc (<NUM>, <NUM>) in the second flexed position abuts the first surface (<NUM>) radially outward and radially inward of the passage (<NUM>); and characterized in that
the orifice disc (<NUM>, <NUM>) includes an orifice (<NUM>, <NUM>) at the passage (<NUM>).