DESC:FIELD OF THE INVENTION
[001] The present disclosure relates to suspension system used for automotive vehicles and more particularly relates to a valve assembly for hydraulic shock absorbers that is applicable to mono, dual and multi tube constructions of shock absorbers to control pressure drop characteristics.
BACKGROUND OF THE INVENTION
[002] The damping mechanism plays a crucial role in preventing excessive bouncing or oscillations within the suspension, promoting improved vehicle stability, control, and overall comfort. When a vehicle encounters road irregularities such as bumps, dips, or vibrations, the hydraulic valves in the suspension comes into action, overseeing the flow of hydraulic fluid. This process transforms the kinetic energy resulting from suspension motion into heat, effectively controlling excessive motion and ultimately providing passengers with a more comfortable and stable travel experience.

[003] A piston and base valve assembly plays a critical role in the functioning of suspension systems, exerting control and dampening effects on suspension movement to achieve a smoother and well-regulated ride. The primary purpose is to manage and alleviate oscillations, vibrations, and disturbances caused by road imperfections like bumps or uneven terrain. The main goal is to absorb or disperse the energy generated by these motions, thereby enhancing ride comfort and stability.

[004] The piston is configured within the piston assembly separating the pressure tube into an upper working chamber and a lower working chamber, with the support of valve assembly and both of these chambers are filled with hydraulic fluid or oil. Within the piston assembly, the plurality of valves on both the rebound and compression sides regulates the movement of hydraulic fluid between these upper and lower working chambers. Additionally, a base valve, positioned within the assembly, controls the flow of hydraulic fluid between the lower working chamber and a reserve chamber.

[005] Reference can be made to related art US 9879747 that discloses a shock absorber includes a valve disc defining two chambers, a flow passage formed in the valve disc, the flow passage allowing communication between the two chambers, a window formed in the valve disc, the window being connected to the flow passage, a valve seat formed on the valve disc, the valve seat surrounding the outer periphery of the window; and a plurality of leaf valves formed in the shape of annular plates, the plurality of leaf valves being stacked on the valve disc. The first leaf valve stacked on the valve disc is provided such that an outer peripheral part is seatable on and separable from the valve seat, and includes a rib recessed on a valve disc side and projecting on an opposite valve disc side at a position facing the valve seat.

[006] The other related art JP2009204147 discloses A damping force generation mechanism 27 includes a passage 26 for running a fluid, and the disc valve 25 opening/closing the passage 26 and composed of a plurality of stacked discs 29 and 30. The disc valve 25 includes: a first disc 29 having at least one projecting part 35; a spacer 31 arranged in a position without interfering with the projecting part(s) 35 and stacked on the first disc 29; and a second disc 30 stacked on the spacer 31 and contacting the projecting part(s) 35.

[007] The one another related art JP2009222124 provide a fluid pressure shock absorber for compatibly suppressing the dispersion of damping force and actualizing smooth operation of disc valves. On the side of a passage 20 for the plurality of disc valves 25, an energizing member 35 is provided whose diameter is smaller than the diameter of a valve seat 19 and which energizes the disc valves 25 in a valve opening direction until the disc valves 25 are opened. The energizing member 35 energizes the disc valves 25 in the valve opening direction until they are opened.

[008] Further, one of the related arts JP2006183775 discloses a hydraulic shock absorber wherein a piston 5 connected to a piston rod 6 is slidably fit into a cylinder 2 sealing the oil liquid. A flow of the oil liquid caused in an extension side oil passage 11 by sliding of the piston 6 is controlled by an orifice 24 and the disc valve 21 to generate damping force. Protruding parts 25A are formed on both radial ends of a disc 25 composing the disc valve 21, discs laminated in a back face side of the protruding part 25 are warped, and a disc 24 is pressed against an outer circumference seat part 20 at a predetermined set load. In the disc valve 21, since lifting is gradually carried out from a portion separated from the protruding part 25A with a small set load toward a protruding part 25A vicinity with a large set load during valve opening, sharp change of the damping force is suppressed, and generation of noise and deterioration of ride comfort can be prevented.

[009] The one another related art JP2008281114 discloses valve structure of the shock absorber that has a valve disc 1 having ports 2a and 2b and annular valve seats 1a and 1b arranged on the outer periphery of the ports 2a and 2b, and leaf valves 10a and 10b laminated on the valve disc 1, seated on the annular valve seats 1a and 1b and opening-closing the ports 2a and 2b, and is characterized by fixing at least one or more of butting plates 1a, 11b, 11c, 13a and 13b for partially increasing deflective rigidity of the leaf valves 10a and 19b, to the back face outer periphery of the leaf valves 10a and 10b.

[0010] Another related art US 8083039 discloses a disc valve assembly for a shock absorber opens due to axial movement of a valve disc. The valve disc is biased against a valve body by a valve spring. The valve spring is designed to provide a circumferentially asymmetrical load biasing the valve disc against the valve body. The disc valve assembly can be used as a piston rebound valve assembly, a piston compression valve assembly, a base valve compression valve assembly or a base valve rebound valve assembly.

[0011] In conventional shock absorbers, a bleed valve disc is commonly employed in both the piston and base valves. The bleed opening, also known as orifice, is typically situated in a straightforward manner, protruding directly outward on a circular disc. This configuration is designed to manage pressure reduction effectively by utilizing a flat circular valve disc arrangement, which is pivotal for attaining the intended pressure drop characteristics. In such cases, preloading is achieved by providing the surface height difference in piston and base valves of the shock absorber. This piston and base valves are produced through mostly by sintering process. There is limitation in tunability aspect once the piston and base valve is produced. Generally, the difference in surface height cannot be considered further as tuning parameter during the valve tuning activity, unless different versions of a piston are available.

[0012] Accordingly, there exists a need for providing a piston valve assembly that can support the preload adjustments during rebound and compression hassle-free.
OBJECT OF THE INVENTION
[0013] An object of the present invention is to provide a better tuning range during the rebound and compression operation for a shock absorber.

[0014] Another object of the present invention is to provide a preloading mechanism that gives better control over the opening of valve disc.

[0015] Yet, another object of the present invention is to optimize the suspension performance in a vehicle based on factors like the type of terrain, the weight of the vehicle, and the desired level of comfort.
SUMMARY OF THE INVENTION
[0016] The present invention relates to suspension system used for automotive vehicles and more particularly relates to a valve assembly for hydraulic shock absorbers that is applicable to mono, dual and multi tube constructions of shock absorbers to control pressure drop characteristics.

[0017] The present invention provides a valve assembly system for hydraulic shock absorber system. The valve assembly system for hydraulic shock absorber system is comprising of a first set of discs, the first set of discs secured at the rebound side of a piston. The first set of discs comprises at least one preload disc (22a), at least one valve disc, at least one bleed disc (22b), at least one backup preload disc and at least one backup disc. The plurality of discs in the first set of discs are configured to allow a flow path for the hydraulic fluid inside the shock absorber tube from one side to another. The valve assembly system for hydraulic shock absorber system is comprising of a second set of discs, the second set of discs secured at the compression side of the piston. The second set of discs comprises at least one preload disc (22a), at least one valve disc, at least one bleed disc (22b), at least one backup preload disc and at least one backup disc. The plurality of discs in the second set of discs are configured to allow a flow path for the hydraulic fluid inside the shock absorber tube from one side to another. The valve assembly system for hydraulic shock absorber system is comprising of a plurality of washers each configured with an opening at the centre to receive a piston rod there through and a spacer in each set of discs separating the valve disc and the preload disc (22a). The valve assembly system for hydraulic shock absorber system is comprising of a plurality of protrusions (23) on each of the preload disc (22a). The protrusions (23) on each of the preload disc (22a) are positioned such that they point towards the adjacent mating disc. Together with an optional spacer disc they form a gap in between the valve discs and preload discs. The preload disc (22a) includes circular or noncircular valve disc. The valve assembly system for hydraulic shock absorber system is comprising of a bleed fluid passage (26) provided at each of the bleed disc (22b). The bleed fluid passage (26) is configured to provide longer flow path for fluid when passing therethrough and to avoid direct hitting of the hydraulic fluid on inner tube of the shock absorber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The invention is illustrated in the figures of the accompanying drawings, which are meant to be exemplary and not limiting, in which like references are intended to refer to like or corresponding things. The objects and advantages of the present invention will become apparent when the disclosure is read in conjunction with the following figures, wherein
Figure 1 illustrates a pictorial representation of an unassembled valve assembly for hydraulic shock absorbers in accordance with an exemplary embodiment of the present invention,
Figure 2 illustrates a pictorial representation of a circular preload disc in the valve assembly for hydraulic shock absorbers in accordance with an exemplary embodiment of the present invention,
Figure 3 illustrates a pictorial representation of a clover shaped preload disc in the valve assembly for hydraulic shock absorbers in accordance with an exemplary embodiment of the present invention,
Figure 4A illustrates valve assembly system in assembled condition, without hydraulic pressure according to one of the embodiments of the present invention.

Figure 4B illustrates valve assembly system in assembled condition, with hydraulic pressure, opening the valve according to one of the embodiments of the present invention.
Figure 5 illustrates an exemplary exploded view of a valve assembly system according to one of the embodiments of the present invention.
[0019] It should be appreciated by those skilled in the art that any 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 disclosure provides a valve assembly for hydraulic shock absorbers for use in automobile suspension systems. The valve assembly disclosed in accordance with the present invention is applicable to mono, dual and multi tube constructions of shock absorbers and wherein hydraulic fluid preferably oil is used as damping medium. More precisely, the disclosure relates to circular, non-circular or other shaped valve disc arrangement which provide protrusion (23)s to control pressure drop characteristics.

[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.”
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.
[0025] 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.

[0026] 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.

[0027] 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).

[0028] 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.

[0029] Referring to the figure 1 to 4(A-B), a valve assembly for hydraulic shock absorber (hereinafter the valve assembly (100)’), in accordance with the present invention is shown. The valve assembly (100) comprises a plurality of valve discs configured to allow a flow path for the hydraulic fluid inside the shock absorber tube from one side to another.

[0030] The valve assembly (100) is configured within a piston assembly, wherein the piston assembly additionally comprises of a piston (10), a sealing assembly, a bump stop, and a rod guide therein.

[0031] The piston (10) is a moving component that moves up and down inside the cylinder of the suspension system (“the cylinder” hereinafter) in response to the suspension. The piston (10) includes specific valving or ports that controls the flow of hydraulic fluid there through, allowing for the controlled absorption and dissipation of energy. The piston (10) is designed as a cylindrical component with two opposite sides forming a tension side and a compression side and each of the tension side and the compression side is configured to receive the valve assembly that regulates the flow of hydraulic fluid preferably oil (“fluid” hereinafter) as the suspension moves. Further a plurality of ports configured in the piston providing fluid flow passages (15) that are defined to generate different pressure drop characteristics inside the shock absorber.

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

[0034] The valve assembly comprises a first set of discs secured at the rebound side and a second set of discs at the compression side of the piston. The individual discs in the first and the second set of discs in the valve assembly providing a passage for the fluid inside the shock absorber cylinder from one end of the piston 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 valve assembly includes a plurality of slender metal discs (22) of varying size and shape, and a plurality of washers each configured with an opening at the centre to receive a piston rod there through. The plurality of discs (22) are designed to provide varying levels of resistance to the movement of the fluid flowing therethrough based on the speed and intensity of the suspension's motion.

[0036] In one of the exemplary embodiments of the present invention, the valve assembly comprises the first set of discs of varying size arranged in rebound side of the piston, similarly, the second set of discs of varying size in compression side of the piston.

[0037] In one of the exemplary embodiments of the present invention, the valve assembly comprises the first set of discs of varying size arranged in ascending order in rebound 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 comprises at least one preload disc (22a), at least one valve disc, at least one bleed disc (22b), at least one backup preload disc and at least one backup disc etc. Similarly, the second set of discs comprises at least one preload disc (22a), at least one valve disc, at least one bleed disc (22b), at least one backup preload disc and at least one backup disc etc. In the embodiment, the valve disc and the preload disc (22a) are separated by a spacer.

[0039] In one of the exemplary embodiments of the present invention, the first set of discs comprises at least one valve disc, and at least one preload disc (22a). Similarly, the second set of discs comprises at least one valve disc, at least one preload disc (22a). At least one bleed disc (22b) is present in the first or second set of discs. In the embodiment, the valve disc and the preload disc (22a) are separated by a spacer.

[0040] In one of the exemplary embodiments of the present invention, the preload disc (22a) in the valve assembly in accordance with the present invention includes a circular or noncircular valve disc. The noncircular valve disc is designed with plurality of lobes with at least one protrusion (23) that forms a gap in between the individual discs. Further, gap between the adjacent lobes in the disc is arranged to allow a flow passage for the fluid inside the shock absorber tube.

[0041] In one of the exemplary embodiments of the present invention, the valve assembly in accordance with the present invention comprises at least one preload disc (22a) provided with at least one lobe resembles a clover shaped design with a protrusion (23) near to the curved edges and a centre hole to receive a piston therethrough.

[0042] In one of the exemplary embodiments of the present invention, the valve assembly in accordance with the present invention comprises at least one preload disc (22a) provided as a circular disc with at least one protrusion (23) near to the curved edge and a centre hole to receive a piston therethrough.

[0043] The protrusion (23)s are provided on preload disc (22a) in such a way that it is positioned straight, pointing towards the adjacent mating disc. This controls the preloading force which is one of the controlling factors in damping force characteristics and helps in achieving the desired consistency in damping force. The preloading by way of introducing protrusions (23) on at least one valve disc provides better and more fine control over the opening of the individual valve discs (22) in the valve assembly. This type of preloading arrangement provides greater tunability option than the conventional preloading arrangement provided in piston.

[0044] In one of the exemplary embodiments of the present invention, three protrusions (23) are configured on the preload disc (22a) with varying dimensions. This helps in attaining sequential opening of valves and to open the valve smoothly during the different flow rates of hydraulic oil used in shock absorbers. The protrusion (23)s on the preload disc (22a) are formed by any one of the techniques selected from adding one or more components to create an assembly of parts adhesively bonding the protrusion (23) component to the valve disc (22), configuring rivet on flat surface of the valve disc, or adding filler material to the valve disc by way of welding or brazing or epoxy dot or glueing or functionally equivalent method. An alternative technique for configuring protrusion (23)s on the valve disc is by local deformation or bending of the valve disc (22) itself.

[0045] In alternative embodiments of the present invention, the protrusion (23)s are introduced at any location with same or different dimension on the flat surface of the valve disc of circular, non-circular or any shaped valve disc to achieve said preloading adjustments.

[0046] In one of the exemplary embodiments of the present invention, the first or second or both set of discs are arranged with at least one lobed disc with a bleed disc (22b) in symmetric and asymmetric configurations.

[0047] In one of the exemplary embodiments of the present invention, each of the bleed disc (22b) in the first and second set is designed with a plurality of lobes, and these lobes are arranged in a manner where they maintain a uniform distance from the centre of the disc, resulting in a symmetrical arrangement.

[0048] In one of the exemplary embodiments of the present invention, each of the bleed disc (22a) in the first and second set is designed with a plurality of lobes of varying size.

[0049] In the alternative embodiments of the present invention, the individual valve discs (22) in the valve assembly are made in identical dimensions or in varying dimensions.

[0050] In one of the exemplary embodiments of the present invention, the valve disc (22) with largest dimension in both first and second set of discs are arranged close to the piston (10) thereon.

[0051] In a preferred embodiment, the bleed disc (22a) has the largest diameter and is made in close contact with the flat surface of the piston in both tension and the compression side.

[0052] In one of the exemplary embodiments of the present invention, the piston (10) is structured with a raised platform (11) on both rebound and the compression sides, in a shape similar to the bleed disc (22b) that is configured in a closest position. This provides a base for the discs in the first and the second set of discs in valve assembly to be aligned closer to the piston (10).

[0053] In other exemplary embodiments of this invention, the novel aspects of this invention, illustrated by exemplary embodiments of the piston valve, are applicable to the base valve. Such embodiments can be made by a person skilled in the art.

[0054] In one of the exemplary embodiments of the present invention, the valve assembly comprises a plurality of discs (22) that are arranged in series configuration with varying width and thickness combinations, which enhances tunability of the shock absorber.

[0055] 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.

[0056] The bump stop includes a rubber or foam component that prevents the shock absorber from bottoming out or becoming fully compressed when the suspension is under heavy load or encounters a large impact.

[0057] The rod guide along with bushes are configured to keep the piston rod centred within the cylinder and allow for smooth and aligned movement. Furthermore, the hydraulic fluid is the fluid inside the suspension system that provides resistance and dampening, which flows through the valving and passages to control the movement of the piston (10).

[0058] In one of the exemplary embodiments of the present invention, the individual components in the piston assembly are designed in such a way that angular or tangential alignment between at least two components is made possible by design features.

[0059] In one of the exemplary embodiments of the present invention, the individual components in the piston assembly are designed in such a way that angular or tangential alignment between at least two components is made possible by the process.

[0060] Figure 5 illustrates an exemplary exploded view of a valve assembly system according to one of the embodiments of the present invention.

[0061] In an implementation according to one of the embodiments of the present invention a valve assembly system for hydraulic shock absorber system is comprising of a first set of discs, the first set of discs secured at the rebound or compression side of a piston. The first set of discs comprises at least one preload disc (22a), at least one valve disc, at least one bleed disc (22b), at least one backup preload disc and at least one backup disc. The plurality of discs in the first set of discs are configured to allow a flow path for the hydraulic fluid inside the shock absorber tube from one side to another. The valve assembly system for hydraulic shock absorber system is comprising of a second set of discs, the second set of discs secured at the other side of the piston. The second set of discs is comprising of disc configuration of plurality of discs including but not limited to at least one preload disc (22a), at least one valve disc, at least one bleed disc (22b), at least one backup preload disc and at least one backup disc. The plurality of discs in the second set of discs are configured to allow a flow path for the hydraulic fluid inside the shock absorber tube from one side to another. The valve assembly system for hydraulic shock absorber system is comprising of a plurality of washers each configured with an opening at the centre to receive a piston rod there through and a spacer in each set of discs separating the valve disc and the preload disc (22a). The valve assembly system for hydraulic shock absorber system is comprising of a plurality of protrusions (23) on each of the preload disc (22a). The protrusions (23) on each of the preload disc (22a) are positioned protruding outward from the surface of the preload disc (22a), preferably in a direction perpendicular to the plane of surface of the preload disc (22a), and pointing towards the adjacent mating disc, to form a gap in between the individual discs. The preload disc (22a) includes circular or noncircular valve disc. The valve assembly system for hydraulic shock absorber system is comprising of a bleed fluid passage (26) provided at each of the bleed disc (22b). The bleed fluid passage (26) is configured to provide longer flow path for fluid when passing therethrough and to avoid direct hitting of the hydraulic fluid on inner tube of the shock absorber.

[0062] In an implementation according to one of the embodiments of the present invention the plurality of individual discs in the first and the second set of discs in the valve assembly are layered in various arrangement to provide a passage for the fluid inside the shock absorber cylinder from one end of the piston to the other, specifically between the tension side and a compression side. The plurality of discs in the first and the second set of discs in the valve assembly are configured to provide varying levels of resistance to the movement of the fluid flowing therethrough based on the speed and intensity of the suspension's motion. The noncircular valve discs in the first and the second set of discs in the valve assembly are comprising of a plurality of lobes with at least one protrusion (23) that forms a gap in between the individual discs. The at least one preload discs in the first and the second set of discs in the valve assembly is comprising of at least one lobe resembling a clover shaped design with a protrusion (23) near to the curved edges and a centre hole to receive a piston therethrough. The at least one preload discs in the first and the second set of discs in the valve assembly is comprising of a circular disc with at least one protrusion (23) near to the curved edge and a centre hole to receive a piston therethrough.

[0063] In an implementation according to one of the embodiments of the present invention The at least three protrusions (23) are configured on the preload disc (22a) with varying dimensions to attain sequential opening of valves and to open the valve smoothly during the different flow rates of hydraulic oil used in shock absorbers. The preloading adjustments are achieved by introducing the protrusions (23) at any location with same or different dimension on the flat surface of the valve disc of circular, non-circular or any shaped valve disc.

[0064] In an implementation according to one of the embodiments of the present invention the each of the bleed disc (22b) in the first and second set is comprising of a plurality of lobes arranged in a symmetrical arrangement where they maintain a uniform distance from the centre of the disc. The bleed fluid passage (26) on the bleed disc (22b) may be positioned away from the curved outer edge of each of the lobes in the bleed disc (22b), preferably towards a side of the lobe. The bleed disc(22b) is comprising of the bleed fluid passage (26) in an outward direction of each lobe configured on the outside curved edge of a lobe, or on an edge on side of the of a lobe. The openings in the bleed disc (22b) can be configured anywhere on the outside edge of the bleed disc (22b). The at least one bleed disc (22b) is comprising of at least one bleed fluid passage (28) arranged in an inclined fashion with respect to the edge. The multiple bleed disc (22b) in the valve assembly system are oriented with respect to each other so that the orifice openings overlaps, creating a larger combined orifice opening.

[0065] In an implementation according to one of the embodiments of the present invention the individual valve discs (22) in the valve assembly system are made in identical dimensions or in varying dimensions. The valve disc (22) with largest dimension in both first and second set of discs are arranged close to the piston (10) thereon.

[0066] In an implementation according to one of the embodiments of the present invention the bleed disc (22a) in the valve assembly system has the largest diameter and is made in close contact with the flat surface of the piston in both tension and the compression side.

[0067] In an implementation according to one of the embodiments of the present invention a plurality of discs (22) in the valve assembly system are arranged in series configuration with varying width and thickness combinations to enhances tunability of the shock absorber.

[0068] In an implementation according to one of the embodiments of the present invention the valve assembly system is configured in a piston assembly comprising of a piston (10), a sealing assembly, a bump stop, and a rod guide. The piston (10) comprises construction as a cylindrical component with two opposite sides forming a tension side and a compression side and each of the tension side and the compression side configured to receive the valve assembly that regulates the flow of hydraulic fluid as the suspension moves. The plurality of ports (25) configured in the piston provide fluid flow passages defined to generate different pressure drop characteristics inside the shock absorber. The raised platform (11) structured in the piston on both rebound and the compression sides is in a shape similar to the disc that is configured in a closest position.

[0069] The present invention a valve assembly system for hydraulic shock absorber system demonstrates a plurality of advantages including but not limited to:
• The non-circular disc arrangement in the valve assembly 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.
• The valve assembly provides better preloading by means of external protrusion (23) mechanism and not only due to difference in surface heights of piston and base valves respectively. Differences in heights of protrusion (23)s and position of protrusion (23) on disc are considered as tuning parameters during valve tuning activity.
• The involvement of circular, non-circular valve disc with protrusion (23)s at any location on the valve disc (22a) helps to control pressure drop characteristics.
• One of the advantages of asymmetric clover shaped valve discs is the possibility to have more control over the opening of the valve discs in the valve assembly and / or reduce the NVH footprint of the opening transition of the valve.
• In the piston assembly (100), a smooth opening of the plurality of discs (22) is provided by means of non-circular shaped valve disc arrangement. In this, one, two or multiple lobes are provided to form a clover shaped disc arrangement and preloaded to avoid the leakage of oil during initial velocities of shock absorber.
• The plurality of lobes in the bleed disc (22b) 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.
• The position of the protrusions (23) can positively influence the opening behavior of the valve, resulting in a more controlled and / or smoother opening.
• The inclined bleed fluid passage (28) serves the purpose of limiting direct impact of hydraulic fluid jet on the inner tube of the shock absorber, resulting in a reduction of noise caused by oil flow within the shock absorber.
• The bleed fluid passage (28)) on the side of the clovers serves the purpose of limiting direct impact of hydraulic fluid jet on the inner tube of the shock absorber, resulting in a reduction of noise caused by oil flow within the shock absorber.
• The inclined bleed fluid passage (28) on the side of the clovers serves the purpose of limiting direct impact of hydraulic fluid jet on the inner tube of the shock absorber, resulting in a reduction of noise caused by oil flow within the shock absorber. In the piston assembly (100), the ports (12) configured on the piston provides a plurality of oil flow passages that are defined to generate different pressure drop characteristics. Further, the clover shaped valve disc arrangement aligns with the inflow and outflow opening in said connected piston ports.
• In the piston assembly (100), the sequential opening of the noncircular discs (22) motivates smooth transition of fluid flow during pre and post blow-off condition. It provides more smooth changes in pressure drop characteristics and fluid flow 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.
[0070] 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, combinations and variations are possible in light of the above. 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 hydraulic shock absorber system, the valve as-sembly system comprises:
a first set of discs, the first set of discs secured at the rebound or compression side of a piston comprises at least one preload disc (22a), at least one valve disc, at least one backup preload disc and the plurality of discs configured to allow a flow path for the hydraulic fluid inside the shock absorber tube from one side to another;
a second set of discs, the second set of discs secured at the other side of the piston comprising disc configuration of plurality of discs, the plurality of discs configured to allow a flow path for the hydraulic fluid inside the shock absorber tube from one side to another;
a plurality of washers each configured with an opening at the center to receive a piston rod there through;
a plurality of protrusions (23) on each of the preload disc (22a) of at least one of the set of discs out of first set of discs and second set of discs, positioned protruding outward from the surface of the preload disc (22a), preferably in a direction perpendicular to the plane of surface of the preload disc (22a) , pointing towards the adjacent mating disc, to form a gap in between the individual discs, the preload disc (22a) includes circular or noncircular valve disc; and
a bleed fluid passage (26) provided at each of the bleed disc (22b).

2. The valve assembly system as claimed in claim 1 further comprises:
at least one bleed disc (22b) each at first set of discs and second set of discs;
at least one backup disc each at first set of discs and second set of discs;
a spacer in each set of discs separating the valve disc and the preload disc (22a).

3. The valve assembly system as claimed in claim 1 wherein the plurality of in-dividual discs in the first and the second set of discs in the valve assembly are layered in various arrangement to provide a passage for the fluid inside the shock absorber cylinder from one end of the piston to the other, specifically between the tension side and a compression side.

4. The valve assembly system as claimed in claim 1 wherein the plurality of discs in the first and the second set of discs in the valve assembly provide varying levels of resistance to the movement of the fluid flowing therethrough based on the speed and intensity of the suspension's motion.

5. The valve assembly system as claimed in claim 1 wherein the noncircular valve discs in the first and the second set of discs in the valve assembly com-prises a plurality of lobes with at least one protrusion (23) that forms a gap in between the individual discs.

6. The valve assembly system as claimed in claim 1 wherein the at least one pre-load discs in the first and the second set of discs in the valve assembly com-prises at least one lobe resembling a clover shaped design with a protrusion (23) near to the curved edges and a center hole to receive a piston therethrough.

7. The valve assembly system as claimed in claim 1 wherein the at least one pre-load discs in the first and the second set of discs in the valve assembly com-prises a circular disc with at least one protrusion (23) near to the curved edge and a center hole to receive a piston therethrough.

8. The valve assembly system as claimed in claim 1 wherein at least three protru-sions (23) are configured on the preload disc (22a) with varying dimensions to attain sequential opening of valves and to open the valve smoothly during the different flow rates of hydraulic oil used in shock absorbers.

9. The valve assembly system as claimed in claim 1 wherein the preloading ad-justments are achieved by introducing the protrusions (23) at any location with same or different dimension on the flat surface of the valve disc of circular, non-circular or any shaped valve disc.

10. The valve assembly system as claimed in claim 1 wherein each of the bleed disc (22b) in the first and second set comprises a plurality of lobes arranged in a symmetrical arrangement where they maintain a uniform distance from the center of the disc.

11. The valve assembly system as claimed in claim 1 wherein the bleed fluid pas-sage (26) may be positioned away from the curved outer edge of each of the lobes in the bleed disc (22b), preferably towards a side of the lobe.

12. The valve assembly system as claimed in claim 1 wherein the bleed disc(22b) comprises the bleed fluid passage (26) in an outward direction of each lobe configured on the outside curved edge of a lobe, or on an edge on side of the of a lobe.

13. The valve assembly system as claimed in claim 1 wherein the openings in the bleed disc (22b) can be configured anywhere on the outside edge of the bleed disc (22b).

14. The valve assembly system as claimed in claim 1 wherein at least one bleed disc (22b) comprises at least one bleed fluid passage (28) arranged in an in-clined fashion with respect to the edge.

15. The valve assembly system as claimed in claim 1 wherein multiple bleed disc (22b) are oriented with respect to each other so that the orifice openings over-laps, creating a larger combined orifice opening.

16. The valve assembly system as claimed in claim 1 wherein the individual valve discs (22) in the valve assembly are made in identical dimensions or in varying dimensions.

17. The valve assembly system as claimed in claim 1 wherein the valve disc (22) with largest dimension in both first and second set of discs are arranged close to the piston (10) thereon.

18. The valve assembly system as claimed in claim 1 wherein the bleed disc (22a) has the largest diameter and is made in close contact with the flat surface of the piston in both tension and the compression side.

19. The valve assembly system as claimed in claim 1 wherein a plurality of discs (22) are arranged in series configuration with varying width and thickness combinations to enhances tunability of the shock absorber.

20. The system as claimed in claim 1 wherein
the valve assembly system is configured in a piston assembly comprising of a piston (10), a sealing assembly, a bump stop, and a rod guide;
the piston (10) having construction as a cylindrical component with two opposite sides forming a tension side and a compression side and each of the tension side and the compression side configured to receive the valve assembly that regulates the flow of hydraulic fluid as the suspension moves;
a plurality of ports (25) configured in the piston providing fluid flow passages defined to generate different pressure drop characteristics inside the shock absorber; and
a raised platform (11) structured on both rebound and the compression sides, in a shape similar to the disc that is configured in a closest position.
Dated this on 26th March, 2025

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