Abstract: A magnetorheological (MR) piston includes an MR piston core, an MR piston end plate, a shim disc, and a flexible orifice disc. The end plate covers an end of the core to define a chamber and has a through passageway aligned with an MR-piston-core bypass passageway at the chamber. The shim disc and the orifice disc are positioned in the chamber. The orifice disc includes an orifice aligned with the bypass passageway at the chamber and includes an additional orifice. Under fluid pressure in a first direction the orifice disc lies substantially flat against one of the end and the MR piston end plate. Under fluid pressure in an opposite second direction the orifice disc is deflected by the presence of the shim disc to lift the additional orifice from the one of the end and the MR piston end plate.

Abstract: A damper includes a rod guide assembly which is attached to an open end portion of a cylinder. The rod guide assembly is adapted to guide a piston rod and to seal damping fluid within the cylinder. The damper includes a compressible rebound bumper disposed between, and attached to one of, the rod guide assembly and a piston. The damper includes a rebound travel limiter. In a first expression, the limiter is adapted to limit the compression of the bumper when the limiter is in contact with the rod guide assembly and the piston. In a second expression, the limiter is in contact with the bumper and the one of the rod guide assembly and the piston, wherein the limiter has a modulus of elasticity which is greater than that of the bumper. A damper subassembly is described which includes a compressible rebound bumper and a rebound travel limiter.

Abstract: One expression of an embodiment of the invention is for a damper including a damper cylinder and a damper gas cup assembly. The damper gas cup assembly is disposed in, and is slidingly engagable with, the damper cylinder and includes a gas-and-liquid-impermeable damper gas cup and a liquid-permeable member. The damper gas cup has a central longitudinal axis and has an outwardly-facing first circumferential surface with a fully-circumferential first surface groove. The first surface groove is adapted to receive a first seal. The member is disposed outside, and is attached to, the damper gas cup and has an outwardly-facing second circumferential surface with a fully-circumferential second surface groove. The second surface groove is adapted to receive a second seal. Another expression of an embodiment of the invention is for the damper gas cup assembly without mention of the damper cylinder.

Abstract: A controlled damper assembly includes a controlled-damper-assembly piston, a controlled-damper-assembly piston rod attached to the piston, an insulated wire, and an electrical connector. The insulated wire is positioned in the piston rod, has a first end operatively connected to the piston, and has a second end. The electrical connector has a first connection terminal electrically connected to the second end of the insulated wire and has a second connection terminal electrically connected to the piston rod. An example, without limitation, of a controlled damper assembly is a magnetorheological damper assembly.

Abstract: A suspension damper including a tube and a damping piston assembly disposed within the tube and slidably mounted therein for reciprocal movement in the tube. The suspension damper also includes a piston rod extending through the tube and connected to the damping piston assembly, a rod guide assembly closing a bottom end of the tube, and a rebound cut-off disk and spring suspended in the tube between the rod guide assembly and the damping piston assembly and cooperating with the damping piston assembly to provide a rebound cut-off effect between the rebound cut-off disk and the damping piston assembly. The rebound cut-off disk and spring have specific gravities that are greater than the specific gravity of the fluid in the tube, such that the disk and the spring sink in the fluid.

Abstract: A controlled damper assembly includes a controlled-damper-assembly piston, a controlled-damper-assembly piston rod attached to the piston, an insulated wire, and an electrical connector. The insulated wire is positioned in the piston rod, has a first end operatively connected to the piston, and has a second end. The electrical connector has a first connection terminal electrically connected to the second end of the insulated wire and has a second connection terminal electrically connected to the piston rod. An example, without limitation, of a controlled damper assembly is a magnetorheological damper assembly.

Abstract: A closing system for use with a magneto-rheological (MR) damper. The closing system provides lubrication for a piston rod without a need for periodic replenishment. According to an embodiment of the present invention, a lubrication chamber of the closing system utilizes a carrier fluid portion of MR fluid present in a fluid reservoir of the damper as lubricant for a piston rod guide and the piston rod. A seal retainer comprised of a porous material acts as a selective barrier to the micro-particles in the MR fluid in the fluid reservoir, allowing the MR carrier fluid portion to pass through the porous seal retainer to the lubrication chamber while restraining the micro-particles in the fluid reservoir. The seal retainer thus acts as a filter to segregate the abrasive particles of the MR fluid and allows the MR carrier fluid portion of the MR fluid to continuously replenish the lubrication chamber and lubrication passage to lubricate the piston rod guide and piston rod.

Abstract: A motor vehicle strut and a rod guide assembly for the same. The strut includes a body, a rod slidable within the body, and a guide assembly. The guide assembly includes a housing assembly with a compliant member positioned adjacent a sleeve. An aperture is formed within the housing assembly. A bearing receives the rod, is positioned substantially within the aperture, and engages the sleeve. At least one seal is positioned substantially within the aperture. A seal cover and a retainer are operably attached to the housing assembly. Lateral movement of the rod causes deformation of the compliant member.

Abstract: A closing system for use with a magneto-rheological (MR) damper. The closing system provides lubrication for a piston rod without a need for periodic replenishment. According to an embodiment of the present invention, a lubrication chamber of the closing system utilizes a carrier fluid portion of MR fluid present in a fluid reservoir of the damper as lubricant for a piston rod guide and the piston rod. A seal retainer comprised of a porous material acts as a selective barrier to the micro-particles in the MR fluid in the fluid reservoir, allowing the MR carrier fluid portion to pass through the porous seal retainer to the lubrication chamber while restraining the micro-particles in the fluid reservoir. The seal retainer thus acts as a filter to segregate the abrasive particles of the MR fluid and allows the MR carrier fluid portion of the MR fluid to continuously replenish the lubrication chamber and lubrication passage to lubricate the piston rod guide and piston rod.

Abstract: A magnetorheological piston includes a body having a substantially magnetically energizable passageway and a substantially magnetically non-energizable passageway. The substantially magnetically non-energizable passageway has a valveless passageway throat and has a flow cross-sectional area which has a minimum at the passageway throat and which is larger away from the passageway throat. A magnetorheological damper includes a cylinder and the above-described magnetorheological piston, wherein the piston is positioned in, and slideably engages, the cylinder.

Abstract: A suspension damper including a tube and a damping piston assembly disposed within the tube and slidably mounted therein for reciprocal movement in the tube. The suspension damper also includes a piston rod extending through the tube and connected to the damping piston assembly, a rod guide assembly closing a bottom end of the tube, and a rebound cut-off disk and spring suspended in the tube between the rod guide assembly and the damping piston assembly and cooperating with the damping piston assembly to provide a rebound cut-off effect between the rebound cut-off disk and the damping piston assembly. The rebound cut-off disk and spring have specific gravities that are greater than the specific gravity of the fluid in the tube, such that the disk and the spring sink in the fluid.

Abstract: A motor vehicle strut and a rod guide assembly for the same. The strut includes a body, a rod slidable within the body, and a guide assembly. The guide assembly includes a housing assembly with a compliant member positioned adjacent a sleeve. An aperture is formed within the housing assembly. A bearing receives the rod, is positioned substantially within the aperture, and engages the sleeve. At least one seal is positioned substantially within the aperture. A seal cover and a retainer are operably attached to the housing assembly. Lateral movement of the rod causes deformation of the compliant member.

Abstract: A hydraulic vehicle damper is provided for limiting the extent and/or speed of extension of the damper on the rebound stroke with a variety of working fluids including magneto-rheological (MR) fluids, through the use of buoyant sleeve in the working chamber of the damper, rather than having rebound limiting elements attached to the damper piston or damper cylinder tube as in prior vehicle dampers.

Abstract: The invention provides a magnetorheological damper assembly and piston. The assembly includes a housing with a fluid carried therein, a piston slidably carried in the housing, a rod and a valve both operably attached to the piston. The piston includes at least one passageway formed therein. The valve includes at least one bypass opening formed therein and at least one variable opening formed between a piston surface and the valve. The valve provides asymmetric fluid flow through the passageway. During operation, the variable opening selectively restricts fluid flow and the bypass opening maintains fluid flow through the passageway.

Abstract: A suspension damper including a tube and a damping piston assembly disposed within the tube and slidably mounted therein for reciprocal movement in the tube. The suspension damper also includes a piston rod extending through the tube and connected to the damping piston assembly, a rod guide assembly closing a top end of the tube, and a rebound cut-off disk and spring suspended in the tube between the rod guide assembly and the damping piston assembly and cooperating with the damping piston assembly to provide a rebound cut-off effect between the rebound cut-off disk and the damping piston assembly. The rebound cut-off disk and spring have specific gravities that are less than the specific gravity of the fluid in the tube, such that the disk and the spring are floatable in the fluid.

Abstract: A top mount for a damper having a piston rod tenon comprises a mount insert and an o-ring. The mount insert is disposed on the tenon, and the o-ring is disposed on the tenon and within a cutout of the mount insert. A damper including the top mount, and a method of assembling a top mount, are also disclosed.

Abstract: A magnetorheological piston includes a magnetorheological-piston coil and a magnetorheological-piston core. The magnetorheological-piston coil has a longitudinal axis. In one expression, the magnetorheological-piston core includes at least two separate core pieces, wherein each of the core pieces is a powder-metal core piece, and wherein the coil is positioned to circumferentially surround at least a portion of at least one of the core pieces. In another expression, the magnetorheological-piston core includes separate upper core, center core, and lower core pieces. The center core piece is located longitudinally between the upper core and lower core pieces and has a circumferential surface positioned radially inward from the inner-diameter portion of the coil. The coil is longitudinally positioned between the upper core and lower core pieces. In one example, each of the upper core, center core, and lower core pieces is a powder-metal core piece.

Abstract: Performance of a vehicle damper utilizing a Magneto-Rheological (MR) fluid is enhanced through use of a piston having grooves in the walls of a magnetic flux path portion of a fluid flow passage through the piston. The grooves result in a focusing and intensification of the magnetic flux emanating from the corners of the grooves, to thereby intensify the magnetic flux impressed across the fluid flow passage and cause a greater degree of change in viscosity of the MR fluid flowing through the passage than is achievable in prior MR dampers having smooth-walled fluid flow passages.

Abstract: A magnetorheological piston includes a body having a substantially magnetically energizable passageway and a substantially magnetically non-energizable passageway. The substantially magnetically non-energizable passageway has a valveless passageway throat and has a flow cross-sectional area which has a minimum at the passageway throat and which is larger away from the passageway throat. A magnetorheological damper includes a cylinder and the above-described magnetorheological piston, wherein the piston is positioned in, and slideably engages, the cylinder.

Abstract: A magnetorheological piston includes a body having a substantially magnetically energizable passageway and a substantially magnetically non-energizable passageway. The substantially magnetically non-energizable passageway has a valveless passageway throat and has a flow cross-sectional area which has a minimum at the passageway throat and which is larger away from the passageway throat. A magnetorheological damper includes a cylinder and the above-described magnetorheological piston, wherein the piston is positioned in, and slideably engages, the cylinder.