DESC:FIELD OF THE INVENTION
[001] The present disclosure relates to automobile shock absorber systems and more particularly relates to a valve assembly for shock absorber system that is applicable to mono, dual and multi tube constructions of shock absorbers wherein hydraulic fluid is used as damping medium.

BACKGROUND OF THE INVENTION
[002] The valve assembly plays a significant role in shock absorber systems by controlling and dampening the movement of the shock absorber, providing a smoother and more controlled ride. This refers to the process of reducing or controlling the oscillations, vibrations, or movements caused by bumps, uneven surfaces, or other disturbances. It involves absorbing or dissipating the energy generated by these movements to provide a smoother and more stable ride. The dampening mechanism also helps to prevent the shock absorber from bouncing excessively or oscillating, thereby improving vehicle stability, control, and comfort. When a vehicle encounters a bump, dip, or vibration on the road, the valve assembly in the shock absorber controls the movement by regulating the flow of hydraulic fluid. This action converts the kinetic energy of the shock absorber movement into heat, effectively dampening the motion and providing a more comfortable and stable ride for the passengers.

[003] Normally, the shock absorber valve assembly is connected to a sprung portion and unsprung portion of the vehicle through a piston rod which extends through the pressure tube. The valve body divides the pressure tube into an upper working chamber and a lower working chamber, both of which are filled with hydraulic oil. Valving on valve assembly limits the flow of oil between upper and lower working chamber. Valving on base valve limits the flow of oil between the lower working chamber and reserve chamber in case of twin tube construction of shock absorber.

[004] Today, a circular valve disc arrangement is commonly employed in piston and base valves for shock absorbers. Reference may be made to a related art EP 2360390 B1 which discloses a shock absorber comprising a pressure tube (18); a piston (12) slidably disposed within the pressure tube (18), said piston (12) dividing said pressure tube (18) into an upper working chamber and a lower working chamber, said piston (12) having a first face and an opposing second face; a plurality of fluid passages extending through said piston (12); a first sealing area disposed on said first face of said piston (12), said first sealing area fully encircling a first one of said plurality of fluid passages; a second sealing area disposed on said first face of said piston (12), said second sealing area fully encircling a second one of said plurality of fluid passages; a first blow-off disc (44) engaging each of said first and second sealing areas; wherein an area encircled by said first sealing area is smaller than an area encircled by said second sealing area.

[005] Another related art US 9169890 B2 discloses a shock absorber. The shock absorber includes a valve assembly which includes a valve disc engaging an inner and outer valve land defined by a valve body. The inner valve land is a non-circular valve land such that a radial dimension between the inner and outer valve land varies based upon a circumferential position of the radial dimension. The varying radial dimension provides a progressive valve opening for the valve assembly.

[006] Another related art US 20070034466 A1 discloses a valve assembly which progressively opens to provide a smooth transition from a closed position to an open position. The fluid pressure reacts against a valve plate in a non-symmetrical manner to progressively open the valve. The valve can include a plurality of varying sized fluid passages or valve lands can be positioned eccentrically to each other to provide a non-symmetrical pressure area.

[007] Another related art WO2022044560A1 claims use of petal shaped disc as a ‘checkvalve’ to prevent flow. However, only one quantity of check valve is used. Protrusions in piston are used to locate the check valve and prevent it from rotating. Use of ‘elastic body’ i.e. spring used to push ‘check valve’ against piston. In last claim, they mention the use of ‘check valve’ on compression side chamber only.

[008] One another related art KR101716831B1 discloses use of petal shaped disc as ‘inter locking prevention unit’ to prevent flow. They are using this on both sides of piston but only one unit on each side. They have specifically claimed that this ‘inter locking prevention unit’ is covering outlet passages of piston. And it allows oil flow by ‘deformed opening’ i.e. it is clamped.

[009] One another related art JP2007120726 discloses using ‘protrusions’ location to control opening, using location of ports to control opening, using different geometry of disc w.r.t. ports to control opening.

[0010] Yet another related art JP2019094934A discloses an annular plate member stacked on the centre side of the valve seat member to form a gap between each of the valve seats.

[0011] The circular valve disc arrangement is commonly employed in piston and base valves for shock absorbers. This arrangement is crucial for achieving the desired pressure drop characteristics. However, the circular shape of the valve disc arrangement presents limitations in controlling the sequential opening of the discs. Ensuring a smooth and controlled opening of the valve disc arrangement is a challenge, but it is essential for achieving consistent damping responses, firm ride control, and enhanced NVH (Noise, Vibration, and Harshness) comfort. To address this challenge and optimize the low-speed control, a wide range of orifice discs is often required. Referring to figured 1, different bending modes of common circular shaped valve discs are shown, wherein the bending modes of circular disc are controlled by bendable distance available on the disc surface. Furthermore, the blow-off point in current, state of the art valving systems is prone to create in NVH. Also tuning of the blow-off point can pose compromises between conflicting requirements.

[0012] Accordingly, there exists need to provide a valve assembly for shock absorber system with a disc assembly that that eliminates the drawbacks of current shock absorber systems.

OBJECT OF THE INVENTION
[0013] An object of the present invention is to provide a rebound and compression operation for the shock absorber systems particularly for a shock absorber.

[0014] Another object of the present invention is to ensure that the shock absorber system responds appropriately to different conditions of vehicles by providing preload adjustments.

[0015] Yet, another object of the present invention is to optimize the shock absorber performance in a vehicle based on factors like the type of terrain, the weight of the vehicle, and the desired level of comforts.

[0016] Yet, another object of the present invention is to align the individual elements and use of alignment between the parts in a disc assembly.

[0017] Yet, another object of the present invention is to use tangential or rotational alignment between the parts in a disc assembly.

BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The objects and advantages of the present invention will become apparent when the disclosure is read in conjunction with the following figures, wherein
Figures 1a-1f illustrate pictorial representation of different bending modes of circular shaped valve discs in a conventional valve assembly in accordance with prior art of the present invention.
Figure 2A illustrates a schematic representation of a valve body and a valve disc in a shock absorber system in accordance with an embodiment of the present invention.
Figure 2 B – 2 D illustrates exploded views of the valve assembly system for a shock absorber system according to one of the embodiments of the present invention.
Figure 3 illustrates a schematic representation of a valve body and a valve disc in assembled state in a shock absorber system in accordance with an embodiment of the present invention.
[0019] It should be appreciated by those skilled in the art that any block diagrams herein represent conceptual views of illustrative systems embodying the principles of the present invention.

DETAILED DESCRIPTION OF THE INVENTION
[0020] The foregoing objects of the invention are accomplished, and the problems and shortcomings associated with prior art techniques and approaches are overcome by the present invention described in the present embodiments.

[0021] The present invention provides a valve assembly for a shock absorber system. The valve assembly comprises a valve body (10), the valve body configured to control fluid flow through it, a disc assembly that provides varying levels of resistance to movement and thereby regulate the flow of hydraulic fluid, a sealing assembly containing seals and O-rings that prevent leaks and uphold the hydraulic, and rod guide and bushings that allows smooth and aligned movement of piston rod. The plurality of discs arranged in the disc assembly provides sequential opening for smooth transition of oil flow from one side of the valve body to the other side during pre and post blow-off condition. This provides a smooth change in pressure drop characteristics and oil velocities inside the cylinder.

[0022] In the following description, for the purpose of explanation, specific details are set forth in order to provide an understanding of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced without these details. One skilled in the art will recognize that embodiments of the present invention, some of which are described below, may be incorporated into several systems.

[0023] Furthermore, connections between components and/or modules within the figures are not intended to be limited to direct connections. Rather, these components and modules may be modified, re-formatted or otherwise changed by intermediary components and modules.

[0024] Throughout this application, with respect to all reasonable derivatives of such terms, and unless otherwise specified (and/or unless the context clearly dictates otherwise), each usage of:
“a” or “an” is meant to read as “at least one.”
“the” is meant to be read as “the at least one.”
[0025] References in the present invention to “one embodiment” or “an embodiment” mean that a particular feature, structure, characteristic, or function described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one of the exemplary embodiments” in various places in the specification are not necessarily all referring to the same embodiment.

[0026] As used in the description herein and throughout the claims that follow, the meaning of "a, an," and "the" includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of "in" includes "in" and "on" unless the context clearly dictates otherwise.

[0027] Exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. These embodiments are provided so that this invention will be thorough and complete and will fully convey the scope of the invention to those of ordinary skilled in the art.

[0028] Moreover, all statements herein reciting embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future (i.e., any elements developed that perform the same function, regardless of structure).

[0029] The present invention is illustrated with reference to the accompanying drawings, throughout which reference numbers indicate corresponding parts in the various figures. These reference numbers are shown in bracket in the following description.

[0030] Referring to the figure 2&3, a valve assembly for shock absorber systems (hereinafter ‘the valve assembly (100)’), in accordance with the present invention is shown. The valve assembly comprises (100) a valve body (10), a disc assembly, a sealing assembly.

[0031] The valve body (10) includes specific valving or ports that control the flow of hydraulic fluid there through, allowing for the controlled absorption and dissipation of energy. The valve body (10) is designed as cylindrical component with two sides forming a tension side and a compression side on opposite ends. Each of the tension side and the compression side is configured to receive the disc assembly that regulates the flow of hydraulic fluid as the shock absorber moves. The valve body (10) is configured with a plurality of ports (25) providing a plurality of oil flow passages that are defined to generate different pressure drop characteristics.

[0032] In one of the exemplary embodiments of the present invention, the valve body (10) is designed as cylindrical component configured with a plurality of flow passages of same dimension connecting both the sides.

[0033] In one of the exemplary embodiments of the present invention, the valve body (10) is designed as cylindrical component configured with a plurality of flow passages of different dimension connecting both the sides.

[0034] The disc assembly comprises a first set of discs secured at the tension side and a second set of discs at the compression side of the valve body (10). The individual discs (22) in the first and the second set of discs in the disc assembly providing a passage for the hydraulic fluid in the cylinder from one end of the valve body (10) to the other, specifically between the tension side and a compression side. The individual elements in the first and the second set of discs are layered in various arrangements in exemplary embodiments to manage the hydraulic fluid's flow, enabling precise adjustments to the shock absorber's performance in accordance with the application.

[0035] In the embodiment, the disc assembly includes a plurality of slender metal discs (22) of varying size and shape, and a plurality of washers each configured with an hole/opening at the centre to receive a piston rod there through. The discs (22) are designed to provide varying levels of resistance to movement of the hydraulic fluid flowing therethrough based on the speed and intensity of the shock absorber's motion.

[0036] In one of the exemplary embodiments of the present invention, the disc assembly (20) comprises the first set of discs of varying size in tension side, similarly, the second set of discs of varying size in compression side. The discs of varying size in each of the set of discs may be sorted according to their outer diameter (hereinafter OD).

[0037] In one of the exemplary embodiments of the present invention, the disc assembly comprises the first set of discs of varying size arranged in ascending order in tension side, similarly, the second set of discs of varying size arranged in descending order in compression side.

[0038] In one of the exemplary embodiments of the present invention, the first set of discs and second set of discs comprises identical set of discs arranged in tension side and compression side of the valve body (10).

[0039] In one of the exemplary embodiments of the present invention, the first set of discs comprises at least one bleed disc, at least one valve disc, at least one preload disc, at least one backup preload disc and at least one backup disc. Similarly, the second set of discs comprises at least one bleed disc, at least one valve disc, at least one preload disc, at least one backup preload disc and at least one backup disc. In the embodiment, the valve disc and the preload disc are separated by a spacer.

[0040] In one of the exemplary embodiments of the present invention, each disc (22) in the first and second set is designed with a plurality of lobes (22a), and these lobes (22a) are arranged in a manner where they maintain a uniform distance from the center of the disc, resulting in a symmetrical arrangement.

[0041] In one of the exemplary embodiments of the present invention, each disc (22) in the first and second set is designed with a plurality of lobes (22a), and these lobes (22a) are arranged in a manner where they maintain a nonuniform distance from the center of the disc, resulting in asymmetrical arrangement.

In one of the exemplary embodiments of the present invention, each disc (22) in the first and second set is designed with a plurality of lobes (22a), and these lobes (22a) are arranged in a manner where they maintain a nonuniform dimension from each other, resulting in asymmetrical arrangement.
[0042] In one of the exemplary embodiments of the present invention, the bleed disc and valve disc are configured with a plurality of lobes, each with at least one lobe at a consistent radial dimension.

[0043] The disc assembly in accordance with the present invention comprises a plurality of discs (22) designed with plurality of lobes (22a) with a gap in between. The gap between the adjacent lobes in each of the discs is arranged to allow a flow passage for the hydraulic fluid inside the cylinder. In the embodiment, the disc (22) with at least three lobes (22a) resembles a clover shaped design with a centre hole/ opening to receive a piston post therethrough. In alternative embodiments, the first and second set of discs are arranged with at least one clover shaped disc (22) in symmetric and / or asymmetric configurations.

[0044] In one of the exemplary embodiments of the present invention, the edges of the non-circular discs with at least some radial component, forming shapes resembling clover structure, may have symmetric orientations.

[0045] In one of the exemplary embodiments of the present invention, the edges of the non-circular discs with at least some radial component, forming shapes resembling clover structure, may have asymmetric orientations.

[0046] In one of the exemplary embodiments of the present invention, the clover shaped discs are replaced with regular circular discs.

[0047] In one of the exemplary embodiments of the present invention, the individual discs (22) in the disc assembly are made in identical dimensions.

[0048] In one of the exemplary embodiments of the present invention, the individual discs (22) in the disc assembly are made in varying dimensions. In one of the exemplary embodiments of the present invention, the disc (22) with largest dimension in both first and second set of discs are arranged close to the valve body (10) on a casting provided thereon. In a preferred embodiment, the preload disc has the largest diameter and is made in close contact with the flat surface of the valve body in both tension and the compression side.

[0049] In one of the exemplary embodiments of the present invention, the discs (22) are stacked in a non sorted order according to the dimension.

[0050] In one of the exemplary embodiments of the present invention, the valve body (10) is structured with a raised platform (11) on both tension and the compression sides, in a shape similar to the disc (22) in closest position. This provides a base for the discs in the first and the second set of discs to be aligned closer to the valve body (10).

[0051] For both uniform and nonuniform configurations, the valve body is constructed to properly receive or seat said uniform and nonuniform discs (22).

[0052] In one of the exemplary embodiments of the present invention, the individual components in the valve assembly (100) are designed in such a way that angular, also known as tangential alignment between at least two components is made possible by design features.

[0053] In one of the exemplary embodiments of the present invention, the individual components in the valve assembly (100) are designed in such a way that angular or tangential alignment between at least two components is made possible by the process.

[0054] In one of the exemplary embodiments of the present invention, the plurality of flow passages aligns, with or without offset, with the radial protrusion(s) of at least one non-circular disc (22).

[0055] In one of the exemplary embodiments of the present invention, the plurality of flow passages aligns, with or without offset, with the radial protrusion(s) of at least one non-circular disc, creating semi- independent parallel hydraulic valves on the valve assembly.

[0056] In one of the exemplary embodiments of the present invention, the center point of the application of the preload on the valve discs can be positioned in an angular manner with respect to the valve discs.

[0057] In one of the exemplary embodiments of the present invention, the center point of the application of the preload on the valve discs can be positioned in an radial manner with respect to the valve discs.

[0058] In other exemplary embodiments of this invention, the novel aspects of this invention, illustrated by exemplary embodiments of the valve assembly, are applicable to the base valve. Such embodiments can be made by a person skilled in the art.

[0059] The preload disc is provided with at least one lobe with an hole/opening, through which the hydraulic fluid can flow.

[0060] Further, the sealing assembly comprises a plurality of seals and O-rings that are configured at various positions and are responsible for maintaining hydraulic fluid integrity within the shock absorber cylinder, facilitating the piston's smooth movement. They prevent leaks and uphold the hydraulic system's efficiency.

[0061] The bump stopper includes a rubber or foam component that prevents the shock absorber from bottoming out or becoming fully compressed when the shock absorber is under heavy load or encounters a large impact.

[0062] The rod guide along with bushes are configured to keep the piston rod centered within the cylinder and allow for smooth and aligned movement. Furthermore, the hydraulic fluid is the fluid inside the shock absorber system that provides resistance and dampening, which flows through the valving and passages to control the movement of the piston.

[0063] In an implementation according to one of the embodiments of the present invention a valve assembly system for a shock absorber system is comprising of a valve body configured to control the fluid flow through it. The valve assembly system for a shock absorber system comprises a disc assembly comprising a plurality of clover shaped discs configured to provide varying levels of resistance to movement thereby regulating the flow of hydraulic fluid as the shock absorber moves. The disc assembly is comprising of a plurality of discs arranged to provide sequential opening for smooth transition of oil flow from one side of the valve body to the other side and provide a smooth change in pressure drop characteristics and oil velocities inside the cylinder. The valve assembly system for a shock absorber system is comprising of a sealing assembly. The sealing assembly may comprise of seals and O-rings. The sealing assembly is configured to prevent leaks and uphold the hydraulic system efficiency.

[0064] In one another implementation according to one of the embodiments of the present invention each of the disc of the plurality of discs of the disc assembly may further comprise a positioning protrusion. The positioning protrusion at each of the disc of the disc assembly is configured to facilitate the positioning of the each if the disc in the disc assembly and in effect positioning of the each if the disc in the valve assembly. The valve assembly system for a shock absorber system is may further comprising of a bump stopper and a rod guide and bushings. The bump stopper is configured to prevent the shock absorber from bottoming out or becoming fully compressed. The rod guide and bushings are configured to allow smooth and aligned movement of piston rod.

[0065] In an implementation according to one of the embodiments of the present invention the valve body of the valve assembly system for a shock absorber system is comprising of cylindrical component with two sides forming a tension side and a compression side on opposite ends. The each of the tension side and the compression side is configured to receive the disc assembly. The disc assembly is configured to regulate the flow of hydraulic fluid as the shock absorber moves. The valve body of the valve assembly system for a shock absorber system comprises a plurality of ports (25) and plurality of port area configured to provide a plurality of oil flow passages defined to generate different pressure drop characteristics. The valve body further comprising of cylindrical component with two sides forming a tension side and a compression side on opposite ends configured with a plurality of flow passages of different dimension connecting both the sides. Further, the valve body (10) is structured with a raised platform (11) on both tension and the compression sides, in a shape similar to the disc (22) in closest position that provides a base for the discs in the first and the second set of discs to be aligned closer to the valve body (10).

[0066] In an implementation according to one of the embodiments of the present invention the disc assembly of the valve assembly system for a shock absorber system is comprising of a first set of discs arranged in a specific order secured at the tension side and a second set of discs of varying size arranged in a specific order at the compression side of the valve body (10). The individual discs (22) in the first and the second set of discs are configured to provide a passage for the hydraulic fluid in the cylinder from one end of the valve body (10) to the other, specifically between the tension side and a compression side. The individual elements in the first and the second set of discs are layered to manage the hydraulic fluid's flow, enabling precise adjustments to the shock absorber's performance. The disc assembly is comprising of at least one disc (22) in the first or second set having a plurality of lobes (22a), with a gap in between the adjacent lobes. The gap between the adjacent lobes in each of the discs is arranged and configured to allow a flow passage for the hydraulic fluid inside the cylinder. The disc (22) with at least three lobes (22a) resembles a clover shaped design with a center hole/opening to receive a piston post therethrough. The at least one disc (22) in both first or second set of discs is arranged close to the valve body (10) on a casting provided thereon. The at least one set of discs of the disc assembly comprises at least one bleed disc, at least one valve disc, at least one preload disc, at least one backup preload disc. The valve assembly is comprising of a plurality of flow passages in the valve configured to direct fluid flow. The valve assembly is comprising of a plurality of discs having a plurality of lobes. The plurality of discs having a plurality of lobes may have asymmetry/symmetry in their geometry. Each disc having a plurality of lobes have a unique configuration to control the opening sequence of the flow passages independently from each other. The unique configuration is controlled by changing the land shape of the valve body for individual clovers and/or changing the shape of individual lobes of the disc. The plurality of discs having a plurality of lobes are arranged in a manner that allows sequential opening of the flow passages, thereby regulating the fluid flow through the valve system. The disc assembly is comprising of at least one set of discs arranged with at least one clover shaped disc (22) in symmetric and / or asymmetric configurations. The disc assembly comprises at least one set of discs arranged with at least two clover shaped discs (22) in symmetric and / or asymmetric configurations. The said at least two clover shaped discs may be identical, similar or different in shape and/or size. The disc assembly is comprising of a plurality of slender metal discs (22) of varying size and shape and/or thickness, and a plurality of washers each configured with an hole/opening at the center to receive a piston rod therethrough. The valve disc and the preload disc of the disc assembly are separated by a spacer. The valve disc is made in close contact with the flat surface of the valve body in both tension and the compression side. The valve disc is provided with at least one lobe with an hole/opening, through which the hydraulic fluid can flow. The preload backup disc is configured to be in contact with the preload disc. The discs (22) of the disc assembly are designed to provide varying levels of resistance to movement of the hydraulic fluid flowing therethrough based on the speed and intensity of the shock absorber's motion.

[0067] In an implementation according to one of the embodiments of the present invention the valve assembly system for a shock absorber system, at least one edge or face of a protrusion or cavity of the valve body aligns, with or without offset, directly or indirectly, with at least one edge of the at least one non-circular disc with an at least partly tangential component in the normal vector of the edge, creating an aligned, hydraulic valves on the valve assembly.

[0068] In an implementation according to one of the embodiments of the present invention the valve body assembly system for a suspension system at least 2 lobes create parallel hydraulic valves. The parallel hydraulic valves can have at least slightly different hydraulic characteristics by changing at least one dimension of the components related to the lobes.

[0069] In an implementation according to one of the embodiments of the present invention the sealing assembly of the valve assembly system for a shock absorber system is comprising of a plurality of seals and O-rings configured at various positions to maintain hydraulic fluid integrity within the shock absorber cylinder, facilitating the piston's smooth movement.

[0070] In an implementation according to one of the embodiments of the present invention the bump stopper of the valve assembly system for a shock absorber system includes a rubber or foam component configured to prevent the shock absorber from bottoming out or becoming fully compressed when the shock absorber is under heavy load or encounters a large impact. The bump stopper acts as a secondary cushion when the shock absorber reaches its maximum compression. It absorbs the excess energy from severe impacts, preventing the suspension from bottoming out and causing damage.

[0071] In an implementation according to one of the embodiments of the present invention the valve assembly system for a shock absorber system comprises at least one endcap. The endcap is configured to provide structural support to the shock absorber, maintaining the integrity of the assembly. This support is vital for withstanding the forces and pressures exerted during operation. It also helps in regulating the flow of hydraulic fluid within the shock absorber.

[0072] In an implementation according to one of the embodiments of the present invention the rod guide along with bushes of the valve assembly system for a shock absorber system are configured to keep the piston rod centered within the cylinder and allow for smooth and aligned movement.

[0073] According to one of the embodiments of the present invention the disc having cloverlike structure in the disc assembly helps to create fully or semi-independent hydraulic valves, allowing more control of the blow-off behavior of the hydraulic valve. One of the advantages of controlling the angular preload position on the valve disc is the possibility to have more control on the opening of these valve discs. One of the advantages of asymmetric clover valve discs is the possibility to have more control over the opening of these valve discs.

[0074] According to one of the embodiments of the present invention the non-circular valve disc arrangement which has asymmetric/asymmetric features helps to control the pressure drop characteristics in shock absorbers. Furthermore, proper alignment between the valve components is essential to enhance the asymmetric characteristics within a valve stack. These features contribute to improved ride comfort and NVH (Noise, Vibration, and Harshness) control.

[0075] According to one of the embodiments of the present invention the in the valve assembly (100), a smooth opening of disc (22) is provided by means of non-circular shaped valve disc arrangement. In this, one, two or multiple lobes (22) are provided to the clover shaped disc arrangement and preloaded to avoid the leakage of oil during initial velocities of shock absorber.

[0076] According to one of the embodiments of the present invention the plurality of lobes (22a) in the discs particularly the clover shape of the discs helps a smooth opening at different time intervals once the oil pressure is cracked/exceeded the preloading pressure of valve disc. This makes no possibility of generating erratic results in damping operation.

[0077] According to one of the embodiments of the present invention the in the valve assembly (100), the ports (12) configured on the valve body provides a plurality of oil flow passages that are defined to generate different pressure drop characteristics. Further, the clover shaped valve disc arrangement completely aligns with the inflow and outflow opening in said connected valve body ports.

[0078] According to one of the embodiments of the present invention the in the valve assembly (100), the sequential opening of the noncircular discs (22) motivates smooth transition of oil flow from laminar to turbulent regime during pre and post blow-off condition. It provides the smooth changes in pressure drop characteristics and oil velocities in blow-off regime. This helps in reduction of NVH issues generated due to shock absorber and provides smooth ride of the vehicle on different road irregularities.

[0079] The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, and to thereby enable others skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but such omissions and substitutions are intended to cover the application or implementation without departing from the scope of the present invention.

,CLAIMS:WE CLAIM:
1. A valve assembly system for a shock absorber system, the valve assembly sys-tem comprises:
a valve body, the valve body configured to control fluid flow through it;
a disc assembly, the disc assembly comprising a plurality of clover shaped disc configured to provide varying levels of resistance to movement thereby regulating the flow of hydraulic fluid as the shock absorber moves, the disc assembly comprising a plurality of discs arranged to provide sequential opening for smooth transition of oil flow from one side of the valve body to the other side and provide a smooth change in pressure drop characteristics and oil velocities inside the cylinder;
a sealing assembly, the sealing assembly, configured to prevent leaks and uphold the hydraulic system efficiency;

2. The system as claimed in claim 1 wherein the valve body comprises:
cylindrical component with two sides forming a tension side and a compression side on opposite ends;
each of the tension side and the compression side configured to receive the disc assembly, the disc assembly configured to regulate the flow of hydraulic fluid as the shock absorber moves; and
a plurality of ports (25) and plurality of port area configured to provide a plurality of oil flow passages defined to generate different pressure drop characteristics.

3. The system as claimed in claim 1 wherein the valve body comprise of cylin-drical component with two sides forming a tension side and a compression side on opposite ends configured with a plurality of flow passages of different di-mension connecting both the sides.

4. The system as claimed in claim 1 wherein the valve body (10) is structured with a raised platform (11) on both tension and the compression sides, in a shape similar to the disc (22) in closest position that provides a base for the discs in the first and the second set of discs to be aligned closer to the valve body (10).

5. The system as claimed in claim 1 wherein the disc assembly comprises:
a first set of discs arranged in a specific order secured at the tension side and a second set of discs of varying size arranged in a specific order at the compression side of the valve body (10);
the individual discs (22) in the first and the second set of discs configured to provide a passage for the hydraulic fluid in the cylinder from one end of the valve body (10) to the other, specifically between the tension side and a compression side; and
the individual elements in the first and the second set of discs layered to manage the hydraulic fluid's flow, enabling precise adjustments to the shock absorber's performance.

6. The system as claimed in claim 1 wherein the disc assembly comprises:
at least one disc (22) in the first or second set configured with a plurality of lobes (22a), with a gap in between the adjacent lobes;
the gap between the adjacent lobes in each of the discs arranged and configured to allow a flow passage for the hydraulic fluid inside the cylinder;
the disc (22) with at least three lobes (22a) resembles a clover shaped design with a center hole/opening to receive a piston post therethrough; and
the at least one disc (22) in both first or second set of discs arranged close to the valve body (10) on a casting provided thereon.

7. The system as claimed in claim 1 wherein at least one set of discs of the disc assembly comprises at least one bleed disc, at least one valve disc, at least one preload disc, at least one backup preload disc

8. The system as claimed in claim 1 wherein the valve assembly comprises:
a plurality of flow passages in the valve configured to direct fluid flow;
a plurality of discs having a plurality of lobes, the plurality of discs having asymmetry/symmetry in their geometry, each disc having a plurality of lobes having a unique configuration to control the opening sequence of the flow passages independently from each other, wherein
said unique configuration controlled by changing the land shape of the valve body for individual clovers and/or changing the shape of individual lobes of the disc; and
said plurality of discs having a plurality of lobes arranged in a manner that allows sequential opening of the flow passages, thereby regulat-ing the fluid flow through the valve system.

9. The system as claimed in claim 1 wherein the disc assembly comprises at least one set of discs arranged with at least one clover shaped disc (22) in symmet-ric and / or asymmetric configurations.

10. The system as claimed in claim 1 wherein the valve assembly comprises at least one set of discs arranged with at least two clover shaped discs (22) in symmetric and / or asymmetric configurations, said at least two clover shaped discs being identical, similar or different in shape and/or size

11. The system as claimed in claim 1 wherein the disc assembly comprises a plu-rality of slender metal discs (22) of varying or same size and/or shape and/or thickness, and a plurality of washers each configured with an opening at the center to receive a piston rod therethrough.

12. The system as claimed in claim 1 wherein the valve disc and the preload disc of the disc assembly are separated by a spacer.

13. The system as claimed in claim 1 wherein the discs (22) of the disc assembly are designed to provide varying levels of resistance to movement of the hy-draulic fluid flowing therethrough based on the speed and intensity of the shock absorber's motion.

14. The system as claimed in claim 1 wherein at least one edge or face of a protru-sion or cavity of the valve body aligns, with or without, offset, directly or indi-rectly, with at least one edge of the at least one non-circular disc with an at least partly tangential component in the normal vector of the edge, creating an aligned, hydraulic valves on the valve assembly.

15. The system as claimed in claim 1 wherein at least 2 lobes create parallel hy-draulic valves.

16. The system as claimed in claim 13 wherein the parallel hydraulic valves can have at least slightly different hydraulic characteristics by changing at least one dimension of the components related to the lobes.

17. The disc assembly of the system as claimed in claim 1 wherein
the valve disc is made in close contact with the flat surface of the valve body in both tension and the compression side;
the valve disc is provided with at least one lobe with an hole/opening, through which the hydraulic fluid can flow.

18. The system as claimed in claim 1 wherein the valve assembly system for a shock absorber system comprises a positioning protrusion at each of the disc of the plurality of discs of the disc assembly.

19. The system as claimed in claim 1 wherein the valve assembly system for a shock absorber system comprises a rod guide and bushings configured to allow smooth and aligned movement of piston rod.

20. The system as claimed in claim 1 wherein the sealing assembly comprises a plurality of seals and O-rings configured at various positions to maintain hy-draulic fluid integrity within the shock absorber cylinder, facilitating the pis-ton's smooth movement.

21. The system as claimed in claim 1 comprises at least one bump stopper wherein the bump stopper includes a rubber or foam component configured to prevent the shock absorber from bottoming out or becoming fully compressed by act-ing as a secondary cushion when the shock absorber is under heavy load or en-counters a large impact.

22. The system as claimed in claim 1 comprises at least one endcap, the endcap configured to provide structural support to the shock absorber.

23. The system as claimed in claim 1 wherein the rod guide along with bushes configured to keep the piston rod centered within the cylinder and allow for smooth and aligned movement.
Dated this on 26th day of March, 2025

Prafulla Wange
(Agent for Applicant)
(IN-PA-2058)