Abstract: A vibration damper includes an end-stop control valve that progressively adds end-of-stroke damping force to complement the damping force provided by a main piston. The end-stop control valve may include a valve piston assembly that has a valve piston insert, a piston that is disposed radially outside the valve piston insert, and a valve disc stack-up that is supported on a hub of the valve piston insert and a valve seat of the piston. The valve piston insert and the piston may be arranged so as to be longitudinally movable relative to one another. Consequently, the preload of the valve disc stack-up increases as the valve piston assembly contacts a catch piston and begins end-of-stroke damping. Transitioning from an initial preload to a maximum preload during the end-of-stroke damping event progressively increases damping resistance and thereby improves NVH characteristics.

Abstract: An end-stop control valve can progressively add end-of-stroke damping resistance to complement the damping force provided by a main piston in a damper tube. The end-stop control valve may include a piston that is secured on a piston rod and selectively engages a catch piston, both of which are longitudinally movable within the damper tube. As the piston approaches the catch piston, an annular pocket of hydraulic fluid is created longitudinally and radially between the piston and the catch piston. As the piston continues to approach the catch piston, a cross-sectional area through which hydraulic fluid exits the pocket decreases, thereby gradually increasing the resistance of the end-stop control valve. In addition, a spring disc secured on the piston rod may contact a valve seat on the catch piston and provide resistance by elastically deforming in a longitudinal direction before the contact surfaces of the piston and catch piston engage.

Abstract: An end-stop control valve can progressively add end-of-stroke damping resistance to complement the damping force provided by a main piston in a damper tube. The end-stop control valve may include a piston that selectively engages with a catch piston, both of which are longitudinally movable within the damper tube. To reduce bypass around the piston, a piston band wrapped at least partially around the piston may engage with a sidewall of the catch piston just prior to engagement of the catch piston and the piston, although at least some hydraulic fluid can flow through a pathway of the piston band. A spring disc that moves with the piston may also engage with the catch piston just prior to engagement between the catch piston and the piston. The spring disc may elastically deform to contribute end-of-stroke resistance leading up to engagement of the piston and the catch piston.