Damper with flexible floating disc

1. A damper system for a vehicle, comprising:

a pressure tube containing a hydraulic fluid;

a piston rod extending within the pressure tube along a longitudinal axis;

a first piston assembly slidably fitted in the pressure tube for movement along the longitudinal axis, the first piston assembly coupled to the piston rod and separating the pressure tube into a first working chamber and a second working chamber, the first piston assembly including a first valve assembly that controls fluid flow between the first working chamber and the second working chamber; and

a damper assembly including a damper housing coupled to the piston rod, a disc chamber, and a flexible floating disc slidably received in the disc chamber, the flexible floating disc being unbiased and free floating in the disc chamber for movement between a first position and a second position, the disc chamber bounded by a proximal chamber surface defining a proximal tapered cavity and a distal chamber surface defining a distal tapered cavity, the flexible floating disc being made of a resilient material such that the flexible floating disc is adapted to flex into the proximal tapered cavity upon making contact with the proximal chamber surface when the flexible floating disc is in the first position and is adapted to flex into the distal tapered cavity upon making contact with the distal chamber surface when the flexible floating disc is in the second position.

2. The damper system of claim 1 , wherein the flexible floating disc lacks fluid passageways such that the flexible floating disc divides the disc chamber into a proximal portion and a distal portion.

3. The damper system of claim 2 , wherein the damper assembly includes an internal cavity inside the damper housing that contains a second piston assembly, the second piston assembly dividing the internal cavity into a proximal chamber and an intermediary chamber, the intermediary chamber of the internal cavity being disposed in fluid communication with the proximal portion of the disc chamber.

4. The damper system of claim 3 , wherein the second piston assembly includes a second valve assembly that controls fluid flow between the proximal and intermediary chambers.

5. The damper system of claim 4 , wherein the piston rod includes a rod passage that extends between the first working chamber and the proximal chamber.

6. The damper system of claim 2 , wherein each of the proximal and distal chamber surfaces has a concave bowl-like shape.

7. The damper system of claim 6 , wherein the resilient material forming the flexible floating disc has a stiffness that permits the flexible floating disc to assume the shape of the proximal and distal chamber surfaces when a pressure differential between the proximal and distal portions of the disc chamber exceeds a predetermined value ranging from 15 to 45 bar of pressure.

8. The damper system of claim 2 , wherein each of the proximal and distal chamber surfaces has a conical funnel-like shape.

9. The damper system of claim 8 , wherein the proximal and distal chamber surfaces slope radially inward at an angle ranging from 47.5 to 62.5 degrees relative to the longitudinal axis.

10. The damper system of claim 2 , wherein the proximal chamber surface includes a first plurality of holes for communicating fluid into and out of the proximal portion of the disc chamber that are arranged at a plurality of different longitudinal positions such that the flexible floating disc sequentially closes off the holes in the first plurality of holes as the flexible floating disc flexes into the proximal tapered cavity and wherein the distal chamber surface includes a second plurality of holes for communicating fluid into and out of the proximal portion of the disc chamber that are arranged at a plurality of different longitudinal positions such that the flexible floating disc sequentially closes off the holes in the second plurality of holes as the flexible floating disc flexes into the distal tapered cavity.

11. The damper system of claim 1 , wherein the flexible floating disc is cylindrical and has a rectangular profile.

12. The damper system of claim 11 , wherein the flexible floating disc has a thickness ranging from 2 to 8 millimeters (mm).

13. The damper system of claim 1 , wherein the floating disc is axially translatable between the first position and the second position.

14. A damper system for a vehicle, comprising:

a pressure tube containing a hydraulic fluid;

a piston rod extending within the pressure tube along a longitudinal axis;

a first piston assembly slidably fitted in the pressure tube for movement along the longitudinal axis, the first piston assembly coupled to the piston rod and separating the pressure tube into a first working chamber and a second working chamber, the first piston assembly including a first valve assembly that controls fluid flow between the first working chamber and the second working chamber; and

a damper assembly including a damper housing coupled to the piston rod, a disc chamber bounded by a proximal chamber surface and a distal chamber surface, and a floating disc slidably received in the disc chamber, the floating disc being unbiased and free floating in the disc chamber for movement between a first position where the floating disc contacts the proximal chamber surface and a second position where the floating disc contacts the distal chamber surface, the disc chamber including a plurality of holes for communicating fluid into and out of the disc chamber that are arranged at a plurality of different longitudinal positions such that the floating disc sequentially closes off the holes in the disc chamber as the floating disc approaches the first and second positions to restrict fluid flow and slow down longitudinal movement of the floating disc.

15. The damper system of claim 14 , wherein the floating disc lacks fluid passageways such that the flexible floating disc divides the disc chamber into a proximal portion and a distal portion.

16. The damper system of claim 15 , wherein the damper assembly includes an internal cavity inside the damper housing that contains a second piston assembly, the second piston assembly dividing the internal cavity into a proximal chamber and an intermediary chamber, the intermediary chamber of the internal cavity being disposed in fluid communication with the proximal portion of the disc chamber.

17. The damper system of claim 16 , wherein the second piston assembly includes a second valve assembly that controls fluid flow between the proximal and intermediary chambers.

18. The damper system of claim 17 , wherein the piston rod includes a rod passage that extends between the first working chamber and the proximal chamber.

19. The damper system of claim 17 , wherein the plurality of holes in the disc chamber including a first plurality of holes and a second plurality of holes, the first plurality of holes extending between the proximal chamber surface and the intermediary chamber and the second plurality of holes extending between the distal chamber surface and the second working chamber.

20. A damper system including a damper assembly for attachment to a piston rod of a vehicle shock absorber having first and second working chambers, the damper assembly comprising:

a damper housing having a proximal end configured to be coupled to the piston rod and a distal end opposite the proximal end;

an end cap coupled to the damper housing, the end cap having an end wall with a through-bore, the end cap and the damper housing cooperating to define an internal cavity;

an internal piston assembly positioned in the internal cavity of the damper housing such that a proximal chamber is defined in the internal cavity between the internal piston assembly and the proximal end of the damper housing;

a piston retainer positioned in the internal cavity of the damper housing longitudinally between the end cap and that internal piston assembly such that an intermediary chamber is defined in the internal cavity between the internal piston assembly and the piston retainer, the piston retainer holding the internal piston assembly in place such that the internal piston assembly does not move longitudinally within the damper housing;

a disc chamber disposed in fluid communication with the intermediary chamber, the disc chamber bounded by a proximal chamber surface positioned on the piston retainer and a distal chamber surface positioned on the end cap, the proximal chamber surface including a proximal tapered cavity and the distal chamber surface including a distal tapered cavity; and

a flexible floating disc slidably received in the disc chamber, the flexible floating disc being unbiased and free floating in the disc chamber for movement between a first position and a second position, the flexible floating disc being made of a resilient material such that the flexible floating disc is adapted to flex into the proximal tapered cavity upon making contact with the proximal chamber surface when the flexible floating disc is in the first position and is adapted to flex into the distal tapered cavity upon making contact with the distal chamber surface when the flexible floating disc is in the second position.

21. The damper system of claim 20 , wherein the proximal chamber surface includes a first plurality of holes that extend through the piston retainer and are arranged at a plurality of different longitudinal positions such that the flexible floating disc sequentially closes off the holes in the first plurality of holes as the flexible floating disc flexes into the proximal tapered cavity and wherein the distal chamber surface includes a second plurality of holes that extend through the end cap and are arranged at a plurality of different longitudinal positions such that the flexible floating disc sequentially closes off the holes in the second plurality of holes as the flexible floating disc flexes into the distal tapered cavity.