Variable radius spring disc for vehicle shock absorber

1. A shock absorber for a vehicle comprising:

a pressure tube defining a fluid chamber;

a piston disposed within the fluid chamber, the piston dividing the fluid chamber into an upper working chamber and a lower working chamber, the piston defining a plurality of passages extending through the piston between the upper working chamber and the lower working chamber; and

a valve disc assembly supported on the piston and controlling a flow of fluid between the upper working chamber and the lower working chamber through the plurality of passages, the valve disc assembly including a variable radius spring disc among a plurality of discs, wherein

the variable radius spring disc has an outer radius that increases continuously and circumferentially from a first circumferential point to a second circumferential point, along an outer perimeter of the variable radius spring disc, and then makes a convex turn followed by a transition from the second circumferential point via a concave turn back to the first circumferential point, and

the valve disc assembly creates a stiffness that varies in relation to a circumference of the variable radius spring disc such that an actuation of the valve disc assembly with respect to the piston varies circumferentially.

2. The shock absorber of claim 1 wherein the variable radius spring disc has an asymmetrical shape.

3. The shock absorber of claim 1 wherein the variable radius spring disc has a maximum outer radius and a minimum outer radius, and a given outer radius measured from a center point to a given point along the outer perimeter has a value between the maximum outer radius and the minimum outer radius.

4. The shock absorber of claim 1 wherein:

the plurality of discs of the valve disc assembly further includes an orifice disc and one or more solid discs, and

the plurality of discs are arranged such that at least one of the one or more solid discs is disposed between the orifice disc and the variable radius spring disc.

5. The shock absorber of claim 1 wherein:

the plurality of discs actuate away from the piston along a first direction to allow fluid flow between the upper working chamber and the lower working chamber, and actuate toward the piston along a second direction opposite to the first direction to prevent fluid flow between the upper working chamber and the lower working chamber,

the first direction corresponds to a direction along which the outer radius of the variable radius spring disc increases, and

the second direction corresponds to a direction along which the outer radius of the variable radius spring disc decreases.

6. The shock absorber of claim 1 wherein:

the piston includes a support land that circumferentially extends along a surface of the piston, and

the plurality of discs of the valve disc assembly further includes an orifice disc and one or more solid discs, the plurality of discs is disposed at the support land and is arranged such that the orifice disc is disposed on the support land and at least one of the one or more solid discs is disposed between the orifice disc and the variable radius spring.

7. The shock absorber of claim 1 wherein:

the variable radius spring disc has a maximum outer radius and a minimum outer radius, and

fluid pressure required to deflect the valve disc assembly from the piston is greater at a portion of the valve disc assembly that aligns with the minimum outer radius than a portion of the valve disc assembly that aligns with the maximum outer radius.

8. The shock absorber of claim 1 wherein the stiffness of the valve disc assembly increases as the outer radius of the variable spring disc increases.

9. The shock absorber of claim 1 wherein:

the valve disc assembly deflects away from the piston along a direction that corresponds to an increase in the outer radius of the variable radius spring disc as fluid pressure increases in the plurality of passages, and

the valve disc assembly actuates to seal the plurality of passages along a direction that corresponds to a decrease in the outer radius of the variable radius spring disc as fluid pressure decreases in the plurality of passages.

10. A shock absorber for a vehicle comprising:

a pressure tube defining a fluid chamber;

a piston disposed within the fluid chamber, the piston dividing the fluid chamber into an upper working chamber and a lower working chamber, the piston defining a plurality of passages extending through the piston between the upper working chamber and the lower working chamber; and

a valve disc assembly engaging the piston and controlling a flow of fluid between the upper working chamber and the lower working chamber through the plurality of passages, the valve disc assembly including a plurality of discs, wherein the plurality of discs includes a helical disc, wherein

the helical disc has an outer radius that increases continuously and circumferentially from a first point to a second point, along an outer perimeter of the helical disc, and then makes a convex turn followed by a transition from the second point via a concave turn back to the first point, and

the valve disc assembly has a stiffness that circumferentially varies based on the outer radius of the helical disc such that the valve disc assembly circumferentially actuates in a wraparound manner along the piston.

11. The shock absorber of claim 10 wherein the stiffness of the valve disc assembly is proportional to a surface area of the helical disc such that the stiffness increases as the surface area of the helical disc increases.

12. The shock absorber of claim 10 wherein the stiffness of the valve disc assembly increases as the outer radius of the helical disc increases and decreases as the outer radius of the helical disc decreases.

13. The shock absorber of claim 10 further comprising:

a reservoir tube; and

a base valve assembly, wherein

the pressure tube is housed in the reservoir tube,

the pressure tube and the reservoir tube define a reservoir chamber,

the base valve assembly controls the flow of fluid between the lower working chamber and the reservoir chamber, and

the base valve assembly includes a second helical disc among a second plurality of discs, the second helical disc has an outer radius that varies circumferentially along an outer perimeter of the second helical disc.

14. The shock absorber of claim 10 wherein:

the plurality of discs of the valve disc assembly further includes an orifice disc and one or more solid discs, and

the plurality of discs are arranged such that at least one of the one or more solid discs is disposed between the orifice disc and the helical disc.

15. The shock absorber of claim 10 wherein:

the plurality of discs actuate away from the piston along a first direction to allow fluid flow between the upper working chamber and the lower working chamber, and actuate toward the piston along a second direction opposite to the first direction to prevent fluid flow between the upper working chamber and the lower working chamber,

the first direction corresponds to a direction along which the outer radius of the helical disc increases, and

the second direction corresponds to a direction along which the outer radius of the helical disc decreases.

16. The shock absorber of claim 10 wherein the helical disc has a maximum outer radius and a minimum outer radius, and fluid pressure required to deflect the valve disc assembly at the maximum outer radius of the helical disc is greater than at the minimum outer radius of the helical disc.

17. A shock absorber for a vehicle comprising:

a pressure tube defining a fluid chamber;

a piston disposed within the fluid chamber, the piston dividing the fluid chamber into an upper working chamber and a lower working chamber, the piston defining a compression passage and a rebound passage, wherein the compression passage and the rebound passage extend through the piston between the upper working chamber and the lower working chamber;

a compression valve assembly engaging the piston, wherein the compression valve assembly controls a flow of fluid through the compression passage; and

a rebound valve assembly engaging the piston and controlling a flow of fluid through the rebound passage, wherein

at least one of the compression valve assembly and the rebound valve assembly includes a variable radius spring disc among a plurality of discs,

the variable radius spring disc has an outer radius that continuously increases from a first point to a second point along an outer perimeter of the variable radius spring disc, and then makes a convex turn followed by a transition from the second point via a concave turn back to the first point, and

the at least one of the compression valve assembly and the rebound valve assembly has a stiffness that circumferentially varies based on the variable radius spring disc.

18. The shock absorber of claim 17 wherein the stiffness of the at least one of the compression valve assembly and the rebound valve assembly increases as the outer radius of the variable radius spring disc increases and decreases as the outer radius of the variable radius spring disc decreases.

19. The shock absorber of claim 17 wherein:

the plurality of discs actuate away from the piston along a first direction to allow fluid flow between the upper working chamber and the lower working chamber, and actuate toward the piston along a second direction opposite to the first direction to prevent fluid flow between the upper working chamber and the lower working chamber,

the first direction corresponds to a direction along which the outer radius of the variable radius spring disc increases, and

the second direction corresponds to a direction along which the outer radius of the variable radius spring disc decreases.

20. The shock absorber of claim 17 wherein the variable radius spring disc has an asymmetrical shape.