Plates and plate assemblies for noise attenuators and other devices and methods of making

Abstract

Plates and plate assemblies for use in noise attenuators and other devices and methods of making the same are described herein. An example disc-shaped plate includes a support frame to be coupled to a body of the noise attenuator. The support frame has a plurality of radially extending ribs. The plate assembly also includes a disc-shaped plate having a plurality of openings that form a flow path to attenuate noise. The disc-shaped plate is coupled to the support frame so that a pressure-induced load on the disc-shaped plate is distributed to the plurality of radially extending ribs of the support frame.

Description

Technical Field

[0001] The present disclosure relates generally to noise eaters and, more particularly, to plates and plate assemblies for use in noise eaters and other devices and methods of making the same. Background Art

[0002] Fluid valves, regulating valves and other process control devices are usually distributed throughout the process control system and / or fluid distribution system to control the flow rate and / or pressure of various fluids (e.g., liquids, gases, etc.). Process control devices can be used to change the characteristics of the fluid, such as pressure, temperature, flow rate, etc. This change in fluid characteristics usually causes a lot of audible noise. For example, fluid regulating valves are usually used to reduce and / or adjust the fluid pressure to a predetermined value. Some fluid regulating valves reduce the inlet pressure to a lower outlet pressure to match downstream demand by limiting the flow through the orifice. However, the fluid flowing through the pressure regulating valve will generate a lot of audible noise. Therefore, a noise attenuator is usually coupled to the outlet of the pressure regulating valve. Known noise attenuators include a series of plates with small openings that form flow channels through the plates. Summary of the invention

[0003] A plate assembly for a noise attenuator disclosed herein includes a support frame to be coupled to a body of the noise attenuator. The support frame has a plurality of radially extending ribs. The plate assembly also includes a disc-shaped plate having a plurality of openings that form a flow path to attenuate noise. The disc-shaped plate is coupled to the support frame so that a load caused by pressure on the disc-shaped plate is distributed to the plurality of radially extending ribs of the support frame.

[0004] The noise attenuator disclosed herein includes a body defining a fluid passage between an inlet and an outlet and a plate assembly coupled to the body. The plate assembly includes a disc-shaped plate disposed in the fluid passage. The disc-shaped plate has a plurality of openings forming a flow path. The plate assembly also includes a support frame disposed downstream of the disc-shaped plate so that a load caused by pressure on the disc-shaped plate is distributed to the support frame.

[0005] The method disclosed herein includes printing a plurality of sector plates via a three-dimensional (3D) printer. The plurality of sector plates have a plurality of openings forming a flow path. When the plurality of sector plates are arranged together, a disc-shaped plate is formed to be disposed in a fluid body to affect the flow of fluid through the fluid body.

[0006] The disc-shaped plate for a noise attenuator disclosed herein includes a plurality of sector plates. The plurality of sector plates have openings defining a flow path. Each of the plurality of sector plates has a first radial edge forming a first mating feature and a second radial edge forming a second mating feature complementary to the first mating feature, so that when the plurality of sector plates are arranged together, the first mating feature of each of the plurality of sector plates is mated with the second mating feature of an adjacent one of the plurality of sector plates.

[0007] A noise attenuator disclosed herein includes a body defining a fluid passage between an inlet and an outlet and a disc-shaped plate disposed in the fluid passage. The disc-shaped plate has a plurality of openings that form a flow path for reducing noise of fluid flowing in the fluid passage. The disc-shaped plate is formed by a plurality of sector plates having mating features such that when the plurality of sector plates are arranged together, a portion of each of the plurality of sector plates overlaps an adjacent one of the plurality of sector plates in an axial direction.

[0008] The method disclosed herein includes printing a plurality of sector plates via a three-dimensional (3D) printer. The plurality of sector plates have an opening defining a flow path. Each of the plurality of sector plates has a first radial edge forming a first mating feature and a second radial edge forming a second mating feature complementary to the first mating feature. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 is a side view of an example regulating valve assembly including an example noise damper in which the example plates and example plate assemblies disclosed herein may be implemented.

[0010] Figure 2 yes Figure 1 A perspective cross-sectional view of an example noise attenuator including an example plate assembly.

[0011] Figure 3 yes Figure 2 A perspective view of an example panel assembly of FIG. The example panel assembly includes a support frame and a disc-shaped panel formed by a plurality of sector-shaped panels.

[0012] Figure 4 yes Figure 3 An example of a plate assembly showing only one perspective view of the sector plates.

[0013] Figure 5 is a sector plate in the sector plate and Figure 3 Cross-section of the supporting frame.

[0014] Figure 6 An example three-dimensional (3D) printer is shown that can be used to print Figure 3 Sector plate.

[0015] Fig. 7A It is possible through Figure 6 An enlarged view of an example opening formed in one of the example sector plates by a 3D printer.

[0016] Figure 7B It is possible through Figure 6 An enlarged view of another example opening formed in one of the example sector plates by a 3D printer.

[0017] Figure 8 yes Figure 3 A perspective view of an example support frame for an example plate assembly.

[0018] Fig. 9 It is possible to Figure 3 An end view of another example support frame for use with an example disc-shaped plate.

[0019] Fig.10 It is possible to Figure 3 A perspective view of another example support frame for use with an example disc-shaped plate.

[0020] Fig.11 It is possible to Figure 3 An end view of another example support frame for use with an example disc-shaped plate.

[0021] Fig.12 is a perspective view of an example housing with several example plate assemblies that may be implemented in a noise eater.

[0022] Fig.13 yes Fig.12 Another perspective of the example shell.

[0023] Fig.14 yes Fig.13 End view of an example shell.

[0024] Fig.15 yes Fig.12 Side view of an example shell.

[0025] Fig.16 is a flow chart representing an example method of manufacturing an example disk-shaped plate and installing the example disk-shaped plate in a fluid body.

[0026] Fig.17 is a perspective view of an example disk-shaped plate formed from a plurality of example sector-shaped plates that may be implemented in a noise attenuator.

[0027] Fig.18 yes Fig.17 Exploded view of an example disc-shaped plate.

[0028] Fig.19 is a perspective cross-sectional view of an example noise attenuator, wherein Fig.17 The example disc-shaped plate is implemented in the example noise attenuator.

[0029] Fig. 20 yes Fig.17 A perspective view of a first sector plate of the example sector plates.

[0030] Fig.21 yes Fig. 20 Another perspective view of the example sector plate.

[0031] Fig. 22 is a perspective view of an example sector plate that may be used to form a disk-shaped plate that may be implemented in a noise attenuator.

[0032] Fig.23 yes Fig. 22 A perspective cross-sectional view of an example sector plate showing an example in which the inner body of the example sector plate is substantially solid.

[0033] Fig.24 yes Fig. 22 A perspective cross-sectional view of an example sector plate showing an example of an internal body of the sector plate having an example internal lattice structure.

[0034] Fig.25 yes Fig.24 A top view of an example sector plate showing an example internal lattice structure

[0035] Fig.26 yes Fig.24 A side cross-sectional view of an example sector plate showing openings of an example internal lattice structure.

[0036] Fig. 27 is through corresponding to Fig. 22 A perspective view of an example disk-shaped plate formed from multiple example sector plates of an example sector plate.

[0037] Figures 28A-28D A plurality of example sector plates are assembled to form Fig. 27 Example sequence of example disc-shaped plates.

[0038] Fig.29 is a diagram showing an example opening extending through an example disk-shaped plate Fig. 27 A perspective cross-sectional view of an example disc-shaped plate.

[0039] Fig.30 is a perspective view of an example disk-shaped plate formed from a plurality of example sector-shaped plates that may be implemented in a noise attenuator.

[0040] Fig.31 Shows Fig.30 An example disc-shaped plate with a first side removed.

[0041] Figures 32 to 43 is a perspective view of an example disk-shaped plate having various shapes of sector-shaped plates that may be implemented in a noise attenuator.

[0042] Fig.44 is a flow chart representing an example method of manufacturing an example disk-shaped plate and installing the example disk-shaped plate in a fluid body.

[0043] The drawings are not drawn to scale. On the contrary, the thickness of the layer or region can be magnified in the drawings. Generally, the same reference numerals will be used throughout the drawings and the accompanying written description to refer to the same or similar parts. As used in this patent, it is indicated that any part (e.g., layer, film, zone, region or plate) is in any way on (e.g., positioned on, located at, arranged or formed, etc.) another upper part, indicating that the part being cited is in contact with another part, or the part being cited is above another part and one or more intermediate parts are located between them. Unless otherwise specified, connection references (e.g., attachment, coupling, connection and combination) should be interpreted broadly and may include intermediate members between a collection of elements and relative movement between elements. Therefore, connection references do not necessarily infer that two elements are directly connected and have a fixed relationship with each other. Declaring that any part is "in contact" with another part means that there is no intermediate part between the two parts.

[0044] When identifying multiple elements or components that can be mentioned separately, the descriptors "first", "second", "third", etc. are used herein. Unless otherwise specified or understood from the context of its use, such descriptors are not intended to confer any meaning of priority, physical order or arrangement or time order in a list, but are only used as labels to refer to multiple elements or components separately for ease of understanding of the disclosed examples. In some examples, the descriptor "first" can be used to refer to an element in a specific embodiment, while different descriptors such as "second" or "third" can be used in the claims to refer to the same element. In such cases, it should be understood that the use of such descriptors is merely for the convenience of referencing multiple elements or components. DETAILED DESCRIPTION

[0045] Many known process control and / or fluid distribution systems (e.g., power generation systems, refinery systems, natural gas distribution plants, fuel storage tanks, etc.) use process control devices or field devices to affect the flow of fluids. For example, pressure regulating valves are used to control the flow rate and / or pressure of various fluids (e.g., liquids, gases, etc.). Known pressure regulating valves include an inlet for receiving fluid from a source at a relatively high pressure and an outlet for providing fluid to downstream equipment at a relatively low pressure than the pressure at the inlet. The inlet pressure of some known pressure regulating valves is reduced to a lower outlet pressure by limiting the flow through the orifice to match downstream demand. For example, a known pressure regulating valve of a process control and / or fluid distribution system receives a fluid (e.g., gas, liquid) having a relatively high and slightly variable pressure from an upstream source and regulates the flow of the fluid to reduce and / or stabilize the pressure to a level suitable for use by downstream equipment (e.g., equipment of a generator, refinery, etc.).

[0046] In some cases, process control devices affect the flow of fluid in a manner that produces audible noise. For example, a pressure regulating valve can significantly reduce the pressure or flow rate of a fluid, which in turn can produce a significant amount of audible noise (e.g., greater than about 85 decibels). Fluid valves are also known to produce a significant amount of audible noise. Therefore, these process control devices can employ noise attenuators or noise reduction devices to reduce the level of audible noise produced by the fluid flowing through the process control device.

[0047] Example noise attenuators are disclosed herein. The noise attenuator includes one or more plates or disks disposed in a fluid channel to induce a pressure drop along a flow path through the fluid channel. The plate includes an opening (e.g., a hole, an aperture) that defines a fluid flow path through the plate and, therefore, through the fluid channel. As the fluid passes through the plate, the pressure of the fluid is gradually reduced along the flow path (e.g., by decreasing a discrete amount, by decreasing a percentage of a previous fluid pressure). The pressure drop caused by the plate achieves a corresponding reduction or attenuation of the noise (e.g., by a discrete decibel level, a percentage of a decibel level produced by a pressure regulating valve).

[0048] In some cases, these noise attenuator plates are exposed to a significant pressure drop across each plate, which can produce relatively high forces on the plates. Such forces on the plates can produce high bending stresses that cause the plates to yield. For example, the forces on the plates can cause portions of the plates to bend, deflect, rotate, and / or otherwise move away from the walls of the fluid channel (e.g., in a downstream direction), thereby reducing the amount of noise attenuation provided by the plates.

[0049] Therefore, some known plates are relatively thick to withstand the structural load requirements caused by the pressure drop. However, because the known thick plates are typically processed from large, thick metal plates that are cut into individual plates and drilled (perforated), these known thick plates are difficult and costly to manufacture. In addition, these known thick plates significantly increase the weight of the noise attenuator, which can complicate transportation, assembly and installation. Other known plates use a central rod that connects and supports the center of the plate. However, this type of support is prone to bending around the peripheral portion of the plate (sometimes referred to as the taco effect). Therefore, the plate still needs to be relatively thick to withstand these forces without showing any noticeable bending. In addition, traditional machining operations for producing these known plates are limited in feature density (e.g., the number and size of flow paths that can be formed in a plate in a given area).

[0050] An example plate assembly is disclosed herein, which includes a thin disc-shaped plate and a support frame for supporting the disc-shaped plate and providing rigidity to the disc-shaped plate. The disc-shaped plate can be coupled to the support frame (e.g., via one or more threaded fasteners), and the support frame is coupled to the body of the attenuator (e.g., via one or more threaded fasteners) so that the disc-shaped plate is disposed in a fluid channel of the attenuator body. The support frame is disposed downstream of the disc-shaped plate so that the load caused by the pressure on the disc-shaped plate is distributed to the support frame. In this way, the support frame prevents or reduces the yielding of the disc-shaped plate caused by the pressure drop across the disc-shaped plate. For example, the support frame can be constructed of steel or aluminum. The support frame can include one or more structural members (e.g., ribs, rings, etc.) that provide a relatively large contact area for supporting the disc-shaped plate while still allowing the fluid to flow freely through the support frame. In this way, the disc-shaped plate can be relatively thin. From an acoustic point of view, the performance of thin plates and thick plates is similar. However, from a flow point of view, the friction loss generated by thin plates is less than that of thick plates. In addition, thin plates are easier to manufacture and have lower costs.

[0051] In some examples disclosed herein, the disc-shaped plate is constructed via an additive manufacturing process, sometimes referred to as three-dimensional (3D) printing. As used herein, additive manufacturing or 3D printing refers to a manufacturing process in which a 3D object is constructed by adding successive adjacent layers of material. These layers are fused together (e.g., naturally or via a subsequent fusion process) to form a 3D object. The material can be any material such as plastic, metal, concrete, etc. Examples of additive manufacturing include stereolithography (SLA), selective laser sintering (SLS), fused deposition modeling (FDM), and multi-jet molding (MJM). 3D printing is advantageous because it wastes less material than known machining operations. Therefore, 3D printing a disc-shaped plate can produce a relatively low-cost noise attenuator. In addition, 3D printing can be used to form high-density features, such as thousands of smaller diameter openings (flow paths) in a plate, which may not be feasible for known machining processes, so 3D printing is advantageous. Smaller diameter openings produce noise at higher acoustic frequencies compared to larger diameter openings. The human hearing range is 20-20,000 Hertz (Hz). Therefore, using a smaller diameter opening tends to shift the noise frequency up to a frequency that is barely audible or not audible to the human ear.

[0052] In some examples, the size of the disc-shaped plate may exceed the printing capacity of the 3D printer. In particular, the diameter of the disc-shaped plate may be larger than the footprint or building platform of the 3D printer. Therefore, in some examples disclosed herein, the disc-shaped plate is formed by a plurality of parts such as sectors or corner parts. For example, the disc-shaped plate can be formed by a plurality of sector-shaped plates. Each sector-shaped plate in the sector-shaped plate can occupy a sector of a circle. For example, the disc-shaped plate can be formed by four sector-shaped plates, each forming 90° (i.e., one quarter) of a circle. When the sector-shaped plates are arranged together, the sector-shaped plates form a complete circle, which defines the disc-shaped plate. In other examples, the disc-shaped plate can be divided into more or fewer sector-shaped plates. In some examples, during the same printing batch, multiple sector-shaped plates are printed simultaneously. In some examples, each of the sector-shaped plates is printed in a vertical orientation so that multiple sector-shaped plates can be printed side by side during the same printing batch. After the sector-shaped plates are constructed, the sector-shaped plates can be coupled to a support frame to form the disc-shaped plate. The support frame is used so that the disc-shaped plate can be formed by one or more parts. In other examples, the disc-shaped plate may be manufactured as a single piece or in multiple parts by conventional machining means (eg, perforated metal, machined plate, stacked metal plates, etc.).

[0053] Also disclosed herein is an example disc-shaped plate formed by a plurality of sector plates without using a support structure (e.g., a support frame) or fasteners (e.g., a threaded fastener). The sector plates can be arranged together to form a disc-shaped plate that can be disposed in a channel of a fluid body such as a noise attenuator body. The disc-shaped plate can be divided into any number of sector plates (e.g., two, three, four, five, etc.). Each of the sector plates has a first radial edge that forms a first mating feature and a second radial edge that forms a second mating feature that is complementary to the first mating feature. When the sector plates are arranged together, the first mating feature of each of the sector plates engages or mates with the second mating feature of one of the adjacent sector plates. In this way, at least a portion of each of the sector plates overlaps with an adjacent sector plate in an axial direction. These mating features are used to interlock the sector plates to reduce or prevent the sector plates from bending or axial displacement under the pressure of the fluid flow. These mating features can be designed to prevent axial displacement in the upstream direction, the downstream direction, or both. Various mating features of different shapes are disclosed herein.

[0054] Once the sector plates are combined into a disc plate, the disc plate can be installed in the attenuator body. In some examples, the peripheral area of ​​the disc plate is clamped between two structures (e.g., the outlet flange of the attenuator body and the inlet flange of the downstream pipe) so that the disc plate fills or covers the fluid channel. This clamping prevents radial and axial movement, and the interlocking mating features prevent bending and axial movement of the sector plate in the fluid channel. Therefore, no support frame or fasteners are required. This greatly reduces manufacturing costs and assembly time and removal or disassembly time.

[0055] In some examples, the fan-shaped plate is constructed via 3D printing. In some examples, multiple fan-shaped plates are printed simultaneously during the same printing batch. In some examples, each fan-shaped plate in the fan-shaped plate is printed in a vertical orientation so that multiple fan-shaped plates can be printed side by side during the same printing batch. As described above, 3D printing is advantageous because material waste is minimal and high feature density (e.g., thousands of small openings) can be formed. In addition, 3D printing is conducive to forming matching features on radial edges, which may be difficult for traditional (subtractive) machining operations. 3D printing can also be used to form complex structures in the fan-shaped plate, such as internal lattice structures. However, in other examples, the fan-shaped plate can be constructed via traditional (subtractive) machining operations.

[0056] Although many of the example plates and plate assemblies disclosed herein are described in conjunction with noise attenuators, it should be understood that the example plates and plate assemblies can be used in other devices that utilize multi-path flow plates. For example, flame arresters similarly use one or more plates with small openings to allow fluid to flow in one direction, but prevent or reduce flame flow in the opposite direction. Any of the examples disclosed herein can also be used as flame arrester plates.

[0057] Turning to the attached figure, Figure 1 An example noise attenuator 100 is shown in which the example panels and / or panel assemblies disclosed herein may be implemented. The example noise attenuator 100 may be used to reduce noise levels in a process control system and / or a fluid distribution system. The example noise attenuator 100 may be coupled to, for example, an outlet of a process control device to reduce noise generated by a fluid flow exiting the process control device.

[0058] exist Figure 1 In the example shown, the noise attenuator 100 is coupled to a fluid regulating valve 102 (e.g., a pressure regulating valve) as part of a fluid regulating valve assembly 104. However, in other examples, the noise attenuator 100 can be coupled to and / or otherwise integrated into any other type of process control device (e.g., a valve) and / or any other device that changes fluid characteristics and generates noise. In the example shown, the fluid regulating valve assembly 104 is used to process a fluid (e.g., natural gas, air, propane, nitrogen, hydrogen, carbon dioxide, etc.) through a passage of the fluid regulating valve 102 between a regulating valve inlet 106 and a regulating valve outlet 108. In this example, the regulating valve inlet 106 receives the fluid from an upstream pipeline 110. The regulating valve 102 receives a fluid at a relatively high pressure (e.g., several hundred pounds per square inch (psi), between about 1200 psi and 1800 psi, etc.) at the regulating valve inlet 106, and reduces the fluid pressure at the regulating valve outlet 108 based on a predetermined or preset setting (e.g., down to about 10 psi, several hundred psi, to a pressure just below the inlet pressure, etc.). Due to the relatively large pressure drop of the fluid as it flows between the regulating valve inlet 106 and the regulating valve outlet 108 and / or the relatively high fluid flow rate of the fluid exiting the regulating valve outlet 108 , the fluid may generate unacceptable noise levels (eg, greater than 85 decibels).

[0059] The example noise attenuator 100 is in fluid communication with the regulating valve outlet 108 and reduces the noise level generated by the fluid regulating valve 102 to an acceptable level (e.g., less than 85 decibels). In this example, the noise attenuator 100 is directly coupled to the regulating valve outlet 108. However, in other examples, a conduit may be disposed between the regulating valve outlet 108 and the noise attenuator 100. The fluid exits the regulating valve outlet 108 and flows through the noise attenuator 100. The noise attenuator 100 is coupled to a downstream conduit 112, which delivers the fluid to a downstream location.

[0060] Figure 2 is a perspective cross-sectional view of an example noise attenuator 100. In the example shown, the noise attenuator 100 includes a fluid body 200 defining a fluid passage 202 between an inlet 204 and an outlet 206. The body 200 has a connector at the inlet 204 for coupling (e.g., via a threaded fastener) to the regulating valve outlet 108 ( Figure 1 ). The body 200 also has an outlet flange 210 at the outlet 206 for coupling (eg, via threaded fasteners) to an inlet flange 212 of the downstream pipe 112. The noise attenuator 100 includes one or more structures to reduce noise of the fluid flowing through the fluid passage 202.

[0061] In the example shown, the noise attenuator 100 includes an example plate assembly 214 constructed according to the teachings of the present disclosure. The plate assembly 214 is coupled to the body 200. The example plate assembly 214 includes an example disc-shaped plate 216 and an example support frame 218. The disc-shaped plate 216 is disposed in the fluid channel 202 and supported by the support frame 218. The diameter of the disc-shaped plate 216 is oriented perpendicular to the central axis 220 of the fluid channel 202. The disc-shaped plate 216 has a diameter that is substantially the same as and / or fills the portion of the fluid channel 202 where the plate assembly 214 is disposed. The disc-shaped plate 216 affects the flow of fluid through the body 200 to reduce audible noise.

[0062] The disk-shaped plate 216 includes openings (eg, apertures, perforations, etc.) defining flow paths through the disk-shaped plate 216 and, therefore, through the fluid passage 202. The openings are Figure 3 . Fluid flows from an upstream source (e.g., from the regulating valve outlet 108) through the disc plate 216 in the fluid passage 202 into the inlet 204 and through the outlet 206 to the downstream pipe 112. The disc plate 216 causes a pressure drop in the flowing fluid, which slows the fluid and reduces the noise caused by the flowing fluid. Thus, in operation, the noise attenuator 100 reduces the noise caused by the flow of fluid through the process control device (e.g., Figure 1 The fluid passage of the fluid regulating valve 102) and / or the fluid regulating valve assembly (e.g., Figure 1FIG. 1 is a diagram of audible noise caused by high energy fluid in the fluid passage 202 of the noise attenuator 100 of the fluid regulating valve assembly 104 .

[0063] In the example shown, the disc-shaped plate 216 is supported in the fluid passage 202 by a support frame 218. The support frame 220 has a flange 222. In some examples, the flange 222 is configured to be coupled between the outlet flange 210 and the inlet flange 212. In the example shown, the flange 222 is disposed in a groove 224 formed in a face 226 of the outlet flange 210. In some examples, the flange 222 is coupled to the body 200 via threaded fasteners (e.g., bolts, screws, etc.). When the inlet flange 212 of the downstream pipe 112 is coupled to the outlet flange 210 of the noise attenuator 100, the flange 222 is sandwiched between the outlet flange 210 and the inlet flange 212. In the example shown, the support frame 218 is disposed downstream of the disc-shaped plate 216 in the fluid passage 202. The support frame 218 prevents or reduces bending in the disc-shaped plate 216 that may be caused by a pressure drop across the disc-shaped plate 216. As such, the disc-shaped plate 216 may be relatively thin, which results in fewer friction losses than a thicker plate.

[0064] In the example shown, a portion of the fluid channel 202 is angled or tapered between the inlet 204 and the outlet 206. This diverging shape of the fluid channel 202 enables the fluid to expand and reduce velocity to dissipate energy of the fluid flow and / or to reduce noise. In other examples, the fluid channel 202 may not be tapered.

[0065] In this example, the plate assembly 214 is coupled to the body 200 at or near the outlet 206. In some examples, this location of the plate or plate assembly is referred to as an end plate. In other examples, the plate assembly 214 can be coupled to the body 200 so that the plate assembly 214 is disposed at another location within the fluid channel 202 (e.g., closer to the inlet 204).

[0066] In the example shown, the noise attenuator 100 includes an additional plate (sometimes referred to as an inner plate) disposed in the fluid passage 202 upstream of the plate assembly 214. The plate 228 engages with a ledge 231 in the plate assembly 214. The plate 228 may be mounted from the inlet 204 and the plate 230 may be mounted from the outlet 206. The plates 228, 230 are coupled via a plurality of rods 232 (one of which is located at Figure 2), which provides support to prevent or reduce bending of the plates 228, 230. The plates 228, 230 include openings that define a flow path through the respective plates 228, 230 to attenuate noise. The plates 228, 230 gradually slow down and reduce the noise of the flowing fluid. In this example, the rod 232 is not coupled to the plate assembly 214. Therefore, in this example, the plate assembly 214 (e.g., the end plate) is not coupled to the plates 228, 230 (e.g., the inner plate). In other examples, the rod 232 may extend to the plate assembly 214 and be coupled to the plate assembly 214. Additionally or alternatively, in some examples, one or more spacers may be disposed between and in contact with the second plate and the disc-shaped plate 216. In such an example, the spacers transfer loads from the plates 228, 230 to the plate assembly 214. In other examples, the noise attenuator 100 may include more or fewer internal plates. In some examples, the noise attenuator 100 may not include any internal plates, such that the disk-shaped plate 216 is the only plate implemented in the noise attenuator 100 .

[0067] Figure 3 2 is a perspective view of an example plate assembly 214 including a disc-shaped plate 216 and a support frame 218. In the example shown, the support frame 218 has a body 300 that is a ring. The disc-shaped plate 216 can be coupled to the body 300 of the support frame 218. In this example, the disc-shaped plate 216 is coupled to the body 300 of the support frame 218 via threaded fasteners 302 (e.g., bolts, screws, etc.) (one of which is in the Figure 3 ). Any number of threaded fasteners may be used. Thus, the disc-shaped plate 216 is removably coupled to the support frame 218. In other examples, the disc-shaped plate 216 may be coupled to the support frame 218 via other chemical and / or mechanical fastening techniques (e.g., press fit joints, welded joints, adhesives, etc.).

[0068] The flange 222 extends outwardly from the body 300. The flange is coupled to the noise attenuator 100 ( Figure 2 ) of the main body 200( Figure 2 ) to place the disc-shaped plate 216 in the fluid channel 202 ( Figure 2 ). The flange 222 has an opening 304 to receive a threaded fastener 306 (e.g., a bolt, a screw, etc.) (one of which is Figure 3 ), for coupling the support frame 218 to the main body 200.

[0069] In the example shown, the disk-shaped plate 216 is formed by a plurality of sector plates. In this example, the disk-shaped plate 216 is formed by three sector plates including a first sector plate 310, a second sector plate 312, and a third sector plate 314. When arranged adjacent to each other, the sector plates 310-314 form the disk-shaped plate 216. In this example, each of the sector plates 310-314 is a 120° sector of a circle. Thus, when the sector plates 310-314 are arranged together, the sector plates 310-314 form a complete 360° circle. In some examples, when the sector plates 310-314 are coupled to the support frame 218, the radial edges of the sector plates 310-314 may contact each other. In other examples, the radial edges may be spaced apart from each other.

[0070] In other examples, the disk-shaped plate 216 can be formed by more or fewer sectors. For example, the disk-shaped plate 216 can be formed by four sectors (e.g., each 90°), five sectors (e.g., each 72°), six sectors (e.g., each 60°), etc. In some examples, forming the disk-shaped plate 216 using multiple sectors enables the disk-shaped plate 216 to be printed in a 3D printer, as disclosed in further detail herein.

[0071] In this example, each of the sector plates 310-314 is identical, i.e., has the same shape and size. Thus, the disc-shaped plate 216 can be easily manufactured by constructing three identical parts, rather than requiring the manufacture of differently shaped parts. In other examples, one or more of the sector plates may be different from the other plates. For example, two of the sector plates may be 140° sectors, and the third sector plate may be 80° sectors.

[0072] Each of the sector plates 310-314 includes a plurality of openings 316 (one of which is referenced on each of the sector plates 310-314). The openings 316 form a flow path through the corresponding sector plate 310-314 to attenuate noise. When the plate assembly 214 is disposed in the fluid passage 202 ( Figure 2 ), the fluid flows through the openings 316, which reduces or attenuates the noise. The openings 316 can have a relatively small cross-sectional size or diameter (e.g., less than 0.5 mm in diameter). In some examples, all openings 316 have the same cross-sectional size or diameter. In some examples, some of the openings 316 can have different cross-sectional sizes or diameters. The support frame 218 has one or more openings behind the disc-shaped plate 216, which are combined with Figure 4 In the example shown, the openings 316 are grouped together into sections or groups that align with the openings in the support frame 218. In some examples, the openings 316 within each group are equally spaced from each other.

[0073] Figure 4 Shows Figure 3 The plate assembly 214 is shown. The second sector plate 312 and the third sector plate 314 and the threaded fasteners 302 and 306 have been removed. Only the first sector plate 310 is shown on the support frame 218. Figure 4 As shown, the body 300 of the support frame 218 includes a plurality of openings 400 (one of which is located at Figure 4 ). The opening 400 has a larger cross-sectional area than the opening 316 in the disc-shaped plate 216. The opening 400 is formed by one or more structural members extending across the body 300. For example, Figure 4 As shown, the support frame 218 has a plurality of radially extending ribs 402 (one of which is located at Figure 4 ) and multiple rings 404 (one of which is in Figure 4 ). The arrangement of the ribs 402 and the rings 404 defines an opening 400 through the body 300. The ribs 402 and the rings 404 provide a large area for supporting the disc plate 216 to prevent or reduce bending of the disc plate 216. In particular, the ribs 402 and the rings 404 create a larger contact area that distributes the pressure-induced load on the disc plate 216 to the support frame 218, which is a thicker, more rigid structure. The size of the total contact area can be determined based on the flow requirements and support requirements. Generally, the smaller the contact area between the disc plate 216 and the support frame 218, the larger the available flow area. However, more contact area between the disc plate 216 and the support frame 218 reduces the plate thickness requirements. In other examples, the support frame 218 may not include any rings. Instead, the support frame 218 may only include one or more ribs. Although the disc plate 216 contacts the support frame 218 in this example, in other examples, one or more spacers may be provided between the disc plate 216 and the support frame 218.

[0074] The support frame 218 is constructed of a rigid material. For example, the support frame 218 can be constructed of steel (e.g., carbon steel, stainless steel, etc.). In other examples, the support frame 218 can be constructed of another material such as aluminum. In some examples, the support frame 218 is constructed via an extrusion process. In other examples, the support frame 218 can be constructed of other materials and / or other manufacturing techniques (e.g., 3D printing). In some examples, the support frame 218 including the flange 222, the body 300, the ribs 402, and the ring 404 is constructed as a single integral part or component. In other examples, the support frame 218 can be constructed of multiple parts coupled together (e.g., via fasteners, welding, etc.).

[0075] As described above, the openings 316 in the disc-shaped plate 216 can be formed into groups that align with the openings 400 in the support frame 218. Therefore, the openings 316 are not formed in the entire disc-shaped plate 216. In some examples, this reduces manufacturing time and cost. For example, this can reduce the amount of time spent drilling or printing (e.g., via a 3D printer) the openings 316. In other examples, the openings 316 can be set in other locations. In some examples, the entire disc-shaped plate 216 is formed with openings.

[0076] In some examples, one or more threaded fasteners 308 ( Figure 3 ) can be used to couple the two sector plates 310-314 to the support frame 218. This reduces the number of threaded fasteners used to couple the sector plates 310-314 to the support frame 218. For example, Figure 4 As shown, the first sector plate 310 has a first radial edge 406. The first radial edge 406 has three grooves 408 (one of which is located at Figure 4 Each of the grooves 408 forms half of a fastener hole. The third sector plate 314 ( Figure 3 ) has a matching groove on the corresponding radial edge forming the other half of the fastener hole. When the third sector plate 314 is placed adjacent to the first sector plate 310, the groove forms the fastener hole. The threaded fastener 308 ( Figure 3 ) extends through the fastener holes and into holes 410 formed in the support frame 218 (one of which is Figure 4 cited in ).

[0077] Figure 5 A cross-sectional area of ​​the support frame 218 is shown. The threaded fasteners 308 (one of which is Figure 5 ) couples the first sector plate 310 to the support frame 218. The threaded fasteners 302 extend through the grooves 408 (one of which is in the first sector plate 310) in the first sector plate 310. Figure 5 ) and pass through corresponding holes 410 in the support frame 218 (one of which is in Figure 5 ). In this example, the hole 410 in the support frame 218 is threaded, but the groove 408 in the first sector plate 310 is not threaded. The second sector plate 312 and the third sector plate 314 can have similar structures and be coupled to the support frame 218. In other examples, one or more of the grooves 408 in the first sector plate, the second sector plate, and / or the third sector plate 310-314 can be threaded.

[0078] As described above, in some examples, the sector plates 310-314 are constructed via 3D printing. For example, the sector plates 310-314 can be constructed by a 3D printer. Therefore, each of the sector plates 310-314 is constructed via a layer of molten material (e.g., metal). 3D printing is advantageous because it can be used to form a plate with a high density of features, such as thousands of small flow paths. In addition, 3D printing can form small features such as opening 316. In this way, the size of the opening 316 can be smaller than the size of the opening formed using known machining techniques.

[0079] In some examples, due to the part processing size limitations of known 3D printers, the disc-shaped plate 216 is formed by multiple parts. In particular, the diameter of the disc-shaped plate 216 can be relatively large, for example, three feet in diameter. Such a large diameter plate may be too large to be built in a conventional 3D printer. Therefore, the disc-shaped plate is divided into smaller pieces, namely, the sector plates 310-316, which are smaller and can be built in a 3D printer. However, if the disc-shaped plate 216 can be printed as a whole in a 3D printer, the disc-shaped plate 216 can be printed as a single integral piece. In some examples, the disc-shaped plate 216 is printed via a 3D printer, while the other plates (e.g., plates 228, 230) of the noise attenuator 100 are constructed via conventional machine operations. In other examples, other plates may also be 3D printed.

[0080] Figure 6 An example 3D printer 600 is shown that can be used to print the fan-shaped plates 310-314. In some examples, the fan-shaped plates 310-314 are printed in a vertical orientation starting from the radial edge or end of the fan-shaped plates 310-314. This allows multiple fan-shaped plates to be built simultaneously in a single printing batch. For example, Figure 6 As shown, the sector plates 310 - 314 can be constructed side by side during the same printing batch. In this way, the entire disc plate 216 can be constructed via the 3D printer 600 .

[0081] In this example, each of the sector plates 310-314 is identical, i.e., has the same shape and size. In this way, three identical part models can be printed via printer 600. The sector plates 310-316 can be constructed of any material that can be printed by a 3D printer. In some examples, the sector plates 310-316 are constructed of carbon steel, 316 stainless steel, aluminum and / or titanium. In other examples, the sector plates 310-316 can be constructed of other materials. In some examples, additives or other ingredients are added to make the raw materials printable via 3D printing. Using 3D printing, the thickness of the sector plates 310-316 can be the same or vary depending on the desired application.

[0082] In some examples, the fan-shaped plates 310-314 are printed simultaneously in the same 3D printer during the same printing batch. In other examples, the fan-shaped plates 310-314 can be formed by the same 3D printer during separate printing batches. In other examples, the fan-shaped plates 310-314 can be formed by different printers at the same time or at different times.

[0083] In some examples, the disk-shaped plate 216 is constructed via 3D printing, while the support frame 218 is constructed via conventional machining techniques (e.g., extrusion, drilling, laser cutting, water jet cutting, etc.). In other examples, the support frame 218 can also be constructed via 3D printing. For example, the support frame 218 can be built into the 3D printer 600.

[0084] Because 3D printing involves building up material layer by layer, 3D printing has limitations when it comes to overhanging surfaces. Most 3D printers have a critical angle, such as 45°. Any surface that will tilt beyond this critical printing angle may require temporary supports. Otherwise, the material may yield or fall apart while printing.

[0085] For example, because the fan-shaped plates 310-314 are printed vertically, the opening 316 may not be formed in a circular shape. Fig. 7A An enlarged view of one of the openings 316 formed in the first sector plate 310 is shown. As shown, the opening 316 is teardrop-shaped. The upper portion of the opening 316 is printed at the maximum allowable angle, which may be 45°, for example. This results in a teardrop-shaped opening. The other openings 316 may have similar shapes. The teardrop-shaped opening does not adversely affect the flow of fluid through the opening 316.

[0086] In other examples, the opening 316 may have a different shape. For example, if the disk-shaped plate 216 is printed in a horizontal orientation, then Figure 7B As shown, the openings 316 can be formed as circles or inverted circles. In other examples, the openings 316 can have different shapes (e.g., hexagons, polygons). The flow path generated by the openings 316 can be axially straight, overlapping, rotated or twisted. In some examples, all openings 316 are the same. In other examples, the openings 316 can have different diameters and / or different shapes. The distance between adjacent openings 316 can be the same or can vary within the disc-shaped plate 216 or within the same noise attenuator.

[0087] In other examples, the disk-shaped plate 216 formed as a single piece or formed from multiple sector plates can be constructed by conventional (subtractive) manufacturing operations. For example, the disk-shaped plate 216 and / or the sector plates 310-314 can be perforated metal plates, machined plates, stacked metal plates, etc. Therefore, the disk-shaped plate 216 can be composed of a single piece of perforated metal plates, stacked perforated metal plates (e.g., coupled via threaded fasteners), a portion of a perforated metal plate, a 3D printed unit (e.g., constructed from metal or plastic), a 3D printed whole or partial unit, and / or a single or partially machined part (single or partial). In some examples, the disk-shaped plate 216 and the support frame 218 include a single integral part or component. For example, the entire plate assembly 214 can be printed as a single part. Although only one disk-shaped plate is coupled to the support frame 218 in the examples shown above, in other examples, multiple disk-shaped plates can be stacked and coupled to the support frame 218. The disk-shaped plates can be coupled via threaded fasteners. In some examples, such as where high back pressure is experienced, a second support frame may be disposed upstream of the disc-shaped plate 216. Thus, the disc-shaped plate 216 may be sandwiched between the two support frames.

[0088] Figure 8 404 and 405. FIG. 4 is a perspective view of an example support frame 218. As described above, the support frame 218 can be constructed from a single integral part or component, or the support frame 218 can be constructed from multiple parts coupled together. As described above, the support frame 218 has an arrangement of structural members (e.g., ribs 402 and rings 404) to support the fluid channel 202 ( Figure 2 ) in the disc-shaped plate 216 ( Figure 3 and Figure 4 ), while also allowing fluid to flow through the support frame 218. The support frame 218 can have other arrangements or layouts of structural components.

[0089] For example, Fig. 9 is an end view of another example support frame 900 that may be used in place of support frame 218 . Support frame 900 has an arrangement of structural members that support disk-shaped plate 216 . Fig.10 is a perspective view of another example support frame 1000 that may be used in place of support frame 218. Support frame 1000 has an arrangement of structural members that support disk-shaped plate 216. Fig.11is an end view of another example support frame 1100 that can be used in place of support frame 218. Support frame 1100 has an arrangement of structural members that support disc plate 216. The size, thickness, and arrangement of the structural members can have an impact on the strength and flow efficiency of the support frame. For example, because support frame 900 has less structure in the center, support frame 900 can have better flow than support frame 1100. However, support frame 1100 can be stronger than support frame 900 because it has added structure in the center and therefore its size can be thinner than support frame 900. As another example, support frame 1000 can have better flow than support frame 218, but because support frame 1000 does not have the center ring in support frame 218, support frame 1000 may be weaker than support frame 218.

[0090] Fig.12 and Fig.13 1 is a perspective view of an example housing 1200 (also referred to as a noise attenuator assembly) that can be used to attenuate noise generated by fluid flowing in a fluid body. For example, the housing 1200 can be mounted on the noise attenuator 100 ( Figure 1 ) of the fluid channel 202 ( Figure 2 ), in addition to or in place of other panels. The example housing 1200 includes multiple panel assemblies that form multiple noise attenuation stages.

[0091] In the example shown, the housing 1200 includes a first plate assembly 1201 including a first disk-shaped plate 1202 for attenuating noise. The first disk-shaped plate 1202 has a plurality of openings 1204 (one of which is located at Fig.12 1202 is a fluidic body (referenced in the accompanying drawings), thereby forming a flow path through the first disc-shaped plate 1202. The first disc-shaped plate 1202 is coupled to and / or otherwise supported by a first support frame 1206, which operates similarly to the support frame 218 disclosed above. When the shell 1200 is disposed in the fluid body, the first support frame 1206 is disposed downstream of the first disc-shaped plate 1202. The first support frame 1206 has a plurality of radially extending ribs 1208. Any number of ribs may be employed. The first support frame 1206 prevents or reduces bending of the first disc-shaped plate 1202 caused by a pressure differential across the first disc-shaped plate 1202. As such, the first disc-shaped plate 1202 may be relatively thin in size compared to known noise attenuator plates because the first disc-shaped plate 1202 does not require structural rigidity to withstand the pressure differential. Such a thin plate is easier and less costly to manufacture.

[0092] In some examples, the housing 1200 includes one or more additional panel components for attenuating noise. Fig.12 and 13As shown, the housing 1200 includes a second plate assembly 1209 and a third plate assembly 1211, the second plate assembly 1209 includes a second disc-shaped plate 1210, and the third plate assembly 1211 includes a third disc-shaped plate 1212. Each of the second disc-shaped plate 1210 and the third disc-shaped plate 1212 has a plurality of openings forming a flow path. The second disc-shaped plate 1210 is coupled to a second support frame 1214 and / or is otherwise supported by the second support frame 1214. The third disc-shaped plate 1212 is coupled to a second support frame 1214 and / or is otherwise supported by the second support frame 1214. In other examples, the housing 1200 may include more than three plate assemblies.

[0093] In some examples, the first disk-shaped plate 1202, the second disk-shaped plate 1210, and the third disk-shaped plate 1212 are coupled to the respective first support frame 1206, the second support frame 1214, and the third support frame 1216 via threaded fasteners. In other examples, the first disk-shaped plate 1202, the second disk-shaped plate 1210, and the third disk-shaped plate 1212 can be coupled to the respective first support frame 1206, the second support frame 1214, and the third support frame 1216 using other chemical and / or mechanical fastening techniques.

[0094] In the example shown, the first plate assembly 1201, the second plate assembly 1209, and the third plate assembly 1211 are coupled to and spaced apart along the center rod 1218. The center rod 1218 is coupled to and extends from the base 1220. To mount the housing 1200 in a fluid body, the base 1220 may be coupled to the fluid body such that the first plate assembly 1201, the second plate assembly 1209, and the third plate assembly 1211 are disposed downstream of the base 1220. For example, the base 1220 may be the body 200 coupled to the noise attenuator 100 near the inlet 204 such that the first plate assembly 1201, the second plate assembly 1209, and the third plate assembly 1211 are disposed in the fluid channel 202.

[0095] In this example, first disk-shaped plate 1202, second disk-shaped plate 1210, and third disk-shaped plate 1212 are perforated plates. First disk-shaped plate 1202, second disk-shaped plate 1210, and third disk-shaped plate 1212 may be constructed via a machining process. In other examples, first disk-shaped plate 1202, second disk-shaped plate 1210, and / or third disk-shaped plate 1212 may be constructed via other manufacturing processes. In some examples, first disk-shaped plate 1202, second disk-shaped plate 1210, and / or third disk-shaped plate 1212 may be constructed via 3D printing (e.g., by Figure 63D printer 600). In this example, each of first disk-shaped plate 1202, second disk-shaped plate 1210, and third disk-shaped plate 1212 is a single integral part or component. In other examples, any of first disk-shaped plate 1202, second disk-shaped plate 1210, and / or third disk-shaped plate 1212 may be constructed from two or more sector-shaped plates, as disclosed in other examples herein.

[0096] In some examples, the support frames 1206, 1214, 1216 are constructed via an extrusion process. For example, a cylindrical material may be extruded into the shape of the support frames 1206, 1214, 1216. The cylinder may then be cut into multiple sections to form individual support frames 1206, 1214, 1216. The support frames 1206, 1214, 1216 may be cut to size (length) based on specific application load requirements. Fig.12 and Fig.13 As shown, the first support frame 1206 is a double frame compared to the second support frame 1214 and the third support frame 1216. Any number of support frames may be used in each of the plate assemblies 1201, 1209, 1211. In other examples, the support frames 1206, 1214, 1216 may be constructed using other manufacturing processes such as 3D printing.

[0097] In some examples, the diameter of the disk-shaped plates 1202, 1210, 1212 is the same as the diameter of their associated support frames 1206, 1214, 1216. In other examples, any of the disk-shaped plates 1202, 1210, 1212 may be larger than their associated support frames 1206, 1214, 1216. For example, Fig.12 and Fig.13 As shown, the diameter of the first disk-shaped plate 1202 is greater than the diameter of the first support frame 1206. The disk-shaped plates 1202, 1210, 1212 are sized to substantially fill the fluid passageway in which the respective disk-shaped plate 1202, 1210, 1212 is to be disposed.

[0098] Fig.14 is an end view of the housing 1200 showing the first disk-shaped plate 1202 and the first support frame 1206 . Fig.15 is a side view of the housing 1200. Fig.15, the plate assemblies 1201, 1209, 1211 are coupled to a center rod 1218. In some examples, more than one rod may be used to connect the plate assemblies 1201, 1209, 1211. In the example shown, the plate assemblies 1201, 1209, 1211 are spaced apart from each other by spacers 1500. The plate assemblies 1201, 1209, 1211 may be spaced apart by any desired distance. In some examples, the spacers 1500 are constructed via an extrusion process. In other examples, the plate assemblies 1201, 1209, 1211 may not be spaced apart. Alternatively, the plate assemblies 1201, 1209, 1211 may be stacked or disposed adjacent to (e.g., in contact with) each other.

[0099] The width of the structural members (e.g., ribs 1208) and the axial length of the support frames 1206, 1214, 1216 can be varied depending on the desired application. For example, a user desiring increased flow can use a support frame with thinner ribs but a greater axial length. In another example, a user desiring significant noise reduction can use a noise attenuator with multiple stages, each of which supports a small pressure drop compared to a noise attenuator with fewer stages.

[0100] Fig.16 is a flow chart representing an example method 1600 of manufacturing and installing a disk-shaped plate in a fluid body of a noise attenuator. The example method 1600 may be used to manufacture and install any of the example disk-shaped plates disclosed herein having multiple plate portions or sectors.

[0101] At block 1602, the example method 1600 includes printing a plurality of sector plates via a 3D printer. Figure 6 As shown, the first fan-shaped plate, the second fan-shaped plate and the third fan-shaped plate 310-314 are printed via a 3D printer 600. The fan-shaped plates 310-314 include an opening 316 forming a flow path. Each fan-shaped plate in the fan-shaped plates 310-314 can be the same size (for example, each is a 120° fan) or different sizes. In some examples, each fan-shaped plate in the fan-shaped plates 310-314 is printed in a vertical orientation. This allows multiple fan-shaped plates to be printed side by side in the same print batch. Therefore, the fan-shaped plates 310-314 can be printed simultaneously as part of the same print batch. In some examples, one or more post-processing operations (for example, drilling, cutting, grinding, etc.) can be performed to smooth the surface of the fan-shaped plates 310-314.

[0102] At block 1604, the example method 1600 includes coupling a plurality of sector plates to a support frame. Figure 3As shown, the sector plates 310-314 are coupled to the support frame 218. In some examples, the sector plates 310-314 are coupled to the support frame 218 via threaded fasteners 302. In some examples, one or more threaded fasteners 308 couple the two sector plates 310-314 to the support frame 218.

[0103] At block 1606, the example method 1606 includes coupling a support frame to a fluid body such that a disk-shaped plate formed by a plurality of sector plates is disposed in a fluid channel of the fluid body. Figure 2 As shown, the support frame 218 is coupled to the body 200 of the noise attenuator 100 such that the disc-shaped plate 216 is disposed in the fluid channel 202. The support frame 218 may be coupled to the body 200 via threaded fasteners 306. In other examples, if the disc-shaped plate 216 is small enough to be printed as one piece in a 3D printer, the entire disc-shaped plate 216 may be printed as a single plate, which may then be coupled to the support frame 218 and disposed in the fluid channel 202.

[0104] If the panel is not composed of multiple panel sectors or parts, the panel can be manufactured as a single piece via 3D printing or by other conventional manufacturing processes (e.g., laser cutting, water jet cutting, drilling, etc.) and similarly coupled to the support frame. Fig.12 The disk-shaped plates 1202, 1210, 1212 in the embodiment are monolithic plates. The disk-shaped plates 1202, 1210, 1212 may be machined plates. The disk-shaped plates 1202, 1210, 1212 are coupled to respective support frames 1206, 1214, 1216, which are then coupled (as a shell) and / or otherwise disposed in a fluid channel of a fluid body.

[0105] In some examples disclosed above, the disc-shaped plate is supported by a support frame. Examples that do not use a support frame are also disclosed herein. Fig.17 is a perspective view of an example disk-shaped plate 1700 constructed in accordance with the teachings of the present disclosure. The example disk-shaped plate 1700 may be used in a noise attenuator to reduce the noise of a flowing fluid. The example disk-shaped plate 1700 is designed to use neither a support structure nor fasteners.

[0106] In the illustrated example, the disk-shaped plate 1700 is formed or defined by a plurality of sector plates. In particular, in this example, the disk-shaped plate 1700 includes a first sector plate 1702, a second sector plate 1704, a third sector plate 1706, and a fourth sector plate 1708. The sector plates 1702-1708 form the disk-shaped plate 1700 when arranged together. In this example, each of the sector plates 1702-1708 forms a 90° sector of a circle when arranged together. In other examples, the disk-shaped plate 1700 may be formed by more or fewer sector plates. For example, the disk-shaped plate 1700 may be formed by five sector plates (e.g., each forming 72° of a circle), six sector plates (e.g., each forming 60° of a circle), etc. In this example, each sector plate 1702-1708 is identical, i.e., forms 90° of the disk-shaped plate 1700. In other examples, the size of one or more of the sector plates 1702 - 1708 may be different. For example, three sector plates may each form 100° of the disk plate 1700 , while the fourth sector plate may form 60° of the disk plate 1700 .

[0107] Each of the sector plates 1702-1708 has a plurality of openings 1710 extending through the corresponding sector plate 1702-1708 (one of which is adjacent to the Fig.17 The openings 1710 form a flow path through the corresponding sector plates 1702-1708 to attenuate noise. The disc-shaped plate 1700 has a first side 1712, a second side 1714 opposite the first side 1712, and a peripheral edge 1716. When the disc-shaped plate 1700 is installed in a fluid body, one of the sides 1712, 1714 faces upstream and one of the sides 1712, 1714 faces downstream.

[0108] In some examples, the fan-shaped plates 1702-1708 are constructed via a 3D printing process. For example, the fan-shaped plates 1702-1708 can be made of Figure 6 The printer 600 of the invention is printed. Therefore, each of the sector plates 1702-1708 is formed via a layer of molten material (e.g., metal). In some examples, the diameter of the disc plate 1700 may be greater than the printing capacity of the 3D printer. Therefore, printing individual sector plates 1702-1708 enables the disc plate 1700 to be constructed by 3D printing. As described above, 3D printing can form extremely small openings. In addition, compared with machining processes, 3D printing wastes the least material. In this example, each sector plate 1702-1708 is identical, that is, has the same shape and size. Therefore, four identical sector plates can be manufactured using the same printing model, which makes manufacturing and assembly easier.

[0109] Fig.18Separate sector plates 1702-1708 are shown. The sector plates 1702-1708 can be pushed together to form the disc-shaped plate 1700. For example, the sector plates 1702-1708 can be placed on a flat surface and pushed radially inward toward each other.

[0110] Each of the sector plates 1702-1708 cooperates or interlocks with two adjacent sector plates 1702-1708. For example, the first sector plate 1702 has a first radial edge 1800, a second radial edge 1802, and a peripheral edge 1803. The first radial edge 1800 forms or includes a first mating feature 1804 and the second radial edge 1802 forms or includes a second mating feature 1806 that is complementary to the first mating feature 1804. The mating features 1804, 1806 may also be referred to as locking features. The mating features 1804, 1806 may be convex and concave features. In this example, the first mating feature 1804 is an angled underhung, and the second mating feature 1806 is an angled overhung that is complementary or opposite to the first mating feature 1804. The second sector plate, the third sector plate, and the fourth sector plate 1704-1708 are the same as the first sector plate 1702. When the sector plates 1702-1708 are assembled into the disk plate 1700, the first mating feature 1804 of each of the sector plates 1702-1708 engages with the second mating feature 1806 of one of the adjacent sector plates 1702-1708 or mates with the second mating feature 1806 of one of the adjacent sector plates 1702-1708. Thus, the first mating feature 1804 of the first sector plate 1702 mates with the second mating feature 1806 of the second sector plate 1704, the first mating feature 1804 of the second sector plate 1704 mates with the second mating feature 1806 of the third sector plate 1706, and so on. In this way, each of the sector plates 1702-1708 overlaps with two adjacent sector plates 1702-1708 in the axial direction. For example, the first sector plate 1702 overlaps the second sector plate 1704 and the fourth sector plate 1708 in the axial direction. As used herein, axial direction refers to a diameter or radius perpendicular to the disc-shaped plate.

[0111] This mating design prevents the sector plates 1702-1708 from axially displacing or moving under the high pressure of the fluid flow. For example, if a uniform force is applied across the first side 1712 (e.g., the side facing upstream) or the second side 1714 (e.g., the side facing downstream) of the disc plate 1700, the first mating feature 1804 and the second mating feature 1806 of each of the sector plates 1702-1708 prevent the sector plates 1702-1708 from collapsing or axially displacing. One force component is transmitted at the contact surfaces of the first mating features 1804 and the second mating features 1806 that are parallel to the first side 1712 and the second side 1714 of the disc plate 1700. The force is generated by the step or other parallel surface feature of the mounting disc plate 1700 (e.g., by Fig.19 Another force component can be transmitted at the inclined surface (e.g., the inclined surfaces of the first and second mating features 1804, 1806) that converts into a radial separation force. This force component is increased by the inner diameter of the cavity of the mounting disc plate 1700 (e.g., by Fig.19 1918 is shown in the figure. Thus, the example mating design can reduce or prevent bending without the need for a support structure or fasteners. Thus, in this example, the plurality of sector plates 1702-1708 are not coupled by fasteners or support structures. In other examples, the shapes of the first mating feature 1804 and the second mating feature 1806 can be different. Various examples of other shape mating features are disclosed herein. The amount of axial overlap can be determined based on the pressure load requirements.

[0112] In some examples, if a uniform load is applied across the disc plate 1700, the mating design resists movement, but if an uneven force (e.g., a point force) is applied to a specific location on one of the sectors 1702-1708, the disc plate 1700 may be fragile and may collapse. Fig.17 As shown, if a point force is applied in the direction of the arrow near the edge of the third sector plate 1706, the point force may generate a torque on the third sector plate 1706, which causes the third sector plate 1706 to twist because there is no overlapping mating feature behind the third sector plate 1706 near the edge. Other example mating feature designs with double overlapping designs are disclosed herein so that the point force does not cause distortion or folding of the sector plates 1702-1708.

[0113] In this example, the sector plates 1702-1708 include openings 1710 (flow paths) along portions of the sector plates 1702-1708 that form the first mating features 1804 and the second mating features 1806. When the sector plates 1702-1708 are assembled in the disc plate 1700, the openings 1710 in the portions of the sector plates 1702-1708 that form the first mating features 1804 and the second mating features 1806 align with corresponding openings 1710 in the first mating features and the second mating features in the adjacent sector plates 1702-1708. In some examples, this maximizes the number of flow paths through the disc plate 1700. In other examples, the sector plates 1702-1708 may not include openings along portions of the sector plates 1702-1708 that form the first mating features 1804 and / or the second mating features 1806.

[0114] Fig.19 1 is a perspective cross-sectional view of an example noise attenuator 1900 in which the example disc-shaped plate 1700 may be implemented. The noise attenuator 1900 includes a body 1902 that defines a fluid passage 1904 between an inlet 1906 and an outlet 1908. The body 1902 has an inlet flange 1910 at the inlet 1906 for coupling (e.g., via threaded fasteners) to an upstream device or pipeline. For example, the inlet flange 1910 may be coupled to Figure 1 and Figure 2 In other examples, the noise attenuator 1900 can be coupled to and / or otherwise integrated with any other type of process control device (e.g., a valve) and / or any other device that changes fluid properties and generates noise. The body 1902 also has an outlet flange 1912 at the outlet 1908 to couple (e.g., via threaded fasteners) to the Fig.19 The inlet flange 1914 of the downstream tube 1916 is shown in FIG.

[0115] In this example, the disc-shaped plate 1700 is disposed at or near the outlet 1908 in the fluid passage 1904. Therefore, the example disc-shaped plate 1700 can be referred to as an end plate. In the illustrated example, the body 1902 includes a recess 1918 formed in the outlet flange 1912 around the outlet 1908. The recess 1918 forms a shoulder 1920 and an inner diameter surface 1921. The disc-shaped plate 1700 is disposed in the recess 1918 so that the outer peripheral area of ​​the first side 1712 of the disc plate engages with the shoulder 1920 and the outer peripheral edge 1716 engages with or is adjacent to the inner diameter surface 1921. The inlet 1924 of the downstream tube 1916 has a diameter smaller than that of the disc-shaped plate 1700. Thus, when the inlet flange 1914 of the downstream tube 1916 is coupled to the outlet flange 1912 of the noise attenuator 1900, the face 1926 of the inlet flange 1914 engages the second side 1714 of the disc-shaped plate 1700. As a result, the peripheral region of the disc-shaped plate 1700 is clamped between the outlet flange 1912 of the body 1902 and the inlet flange 1914 of the downstream tube 1916. This clamping prevents radial and axial displacement of the disc-shaped plate 1700. In some examples, the shoulder 1920 and the face 1926 are in direct contact with the disc-shaped plate 1700. In other examples, one or more spacers may be disposed between the shoulder 1920 and the disc-shaped plate 1700 and / or between the face 1926 and the disc-shaped plate 1700.

[0116] In the example shown, the thickness or depth of the recess 1918 is the same as the disc plate 1700. This helps prevent leakage in the radial direction that may occur between the sector plates 1702-1708. In addition, compared to known attenuators, this design also eliminates the need for end plate O-rings to seal the body 1902 and / or end plate bolts to the body 1902.

[0117] In addition, as disclosed above, the fan-shaped plates 1702-1708 ( Fig.17) prevents the sector plates 1702-1708 from axially shifting and / or folding under the pressure of fluid flowing through the disc plate 1700. The mating features can be designed to prevent axial separation in the upstream direction, the downstream direction, or both. Therefore, the example disc plate 1700 does not require threaded fasteners or support structures (e.g., a central shaft, a support frame, etc.). In this example, the disc plate 1700 is supported only by clamping of the peripheral area of ​​the disc plate 1700. Eliminating the need for fasteners eliminates many of the disadvantages experienced by fasteners. For example, fasteners become loose over time and may need to be re-tightened. Fasteners also typically require support structures. In addition, fasteners can create a limited joint surface that is subject to high stress. On the other hand, the example mating feature design provides a larger, less stressed joint surface. In addition, without fasteners, assembly is easier because the disc plate 1700 can be easily inserted into the recess 1918 before coupling the outlet flange 1912 of the body 1902 to the inlet flange 1914 of the downstream pipe 1916. This reduces the costs associated with assembling the noise attenuator 1900. Additionally, because the disk-shaped plate 1700 is sized to fit a particular recess, the disk-shaped plate 1700 can be made as thick as the structure requires, thereby eliminating the need for adjacent support structures.

[0118] In other examples, the fan-shaped panels 1702-1708 can be coupled or supported by fasteners or support structures, such as in the case of remote assembly or temporary shelf storage (external to the body 1902). In some examples, the board-to-board interface can be strengthened with glue, bonding elements, fasteners, or external retaining rings.

[0119] In the example shown, the noise attenuator 1900 includes additional plates 1930, 1932 (sometimes referred to as inner plates) disposed in the fluid passage 1904 upstream of the disc-shaped plate 1700. In the example shown, the plates 1930, 1932 are connected via a plurality of rods 1934 (one of which is located at the bottom) that prevent or reduce bending of the plates 1930, 1932. Fig.19 ) are coupled. Plates 1930, 1932 include openings that define a flow path through the respective plates 1930, 1932 to attenuate noise. Plates 1930, 1932 gradually slow down and reduce the noise of the flowing fluid. In this example, rod 1934 is not coupled to disc-shaped plate 1700. Therefore, in this example, disc-shaped plate 1700 (e.g., end plate) is not coupled to plates 1930, 1932 (e.g., inner plate). In other examples, rod 1934 may extend to and be coupled to disc-shaped plate 1700. Additionally or alternatively, in some examples, one or more spacers may be disposed between each of plates 1930, 1932 and / or between plate 1932 and disc-shaped plate 1700. For example, Fig.19An example spacer 1936 is shown disposed between the plate 1932 and the disc-shaped plate 1700. Thus, the upstream pressure load from the plates 1930, 1932 is transferred to the disc-shaped plate 1700 via the spacer 1936. In other examples, more spacers may be used. In other examples, no spacers may be disposed between the plate 1938 and the disc-shaped plate 1700. In other examples, more or fewer plates may be implemented. In this example, each of the plates 1930-1938 is a single piece of perforated metal plate. However, in other examples, one or more of the plates 1930-1938 may be the same as the disc-shaped plate 1700. Thus, multiple disc-shaped plates 1700 may be implemented. The separation distance between the plates may be achieved by axial spacers, hole steps, nuts, etc. In other examples, the noise attenuator 1900 may not include any internal plates, so that the disc-shaped plate 1700 may be the only plate implemented in the noise attenuator 1900.

[0120] Fig. 20 and Fig.21 17 is a perspective view of the first sector plate 1702. The first sector plate 1702 has a first radial edge 1800 forming a first mating feature 1804 and a second radial edge 1802 forming a second mating feature 1806. As described above, in some examples, the first sector plate 1702 is constructed by a 3D printer, for example Figure 6 3D printer 600. In some examples, the first sector plate 1702 is printed in a vertical direction, starting from the second radial edge 1802, such as Fig. 20 This allows multiple sector plates to be printed side by side during the same print batch, similar to Figure 6 In some examples, this results in the opening 1710 being teardrop-shaped, similar to Fig. 7A 316 shown in FIG. In other examples, the shape of opening 1710 may be different. In other examples, first fan-shaped plate 1702 may be printed in a different orientation (eg, horizontal).

[0121] In some examples, the flow path formed by the opening 1710 is not uniformly shaped, but rather is formed on the upstream side (eg, first side 1712 ( Fig.17 )) and the downstream surface (eg, the second side 1714 ( Fig.17 )) with variable areas and cross-sectional profiles between. For example, in acoustic applications, one or more openings 1710 can have two or more expansion stages, which improves noise reduction. In another example where only one expansion stage is implemented, the first portion (e.g., 80%) of the flow path can be formed by a larger hole, followed by a smaller hole at the downstream face.

[0122] Fig. 222 is a perspective view of another example sector plate 2200 that can be used to form a disk-shaped plate for a noise attenuator, similar to the sector plates 1702-1708 disclosed above. A plurality of sector plates 2200 can be constructed and arranged together to form a disk-shaped plate. In particular, in this example, four sector plates 2200 can be arranged together to form a disk-shaped plate, an example of which is shown in FIG. Fig. 27 The resulting disc-shaped plate can be arranged in a fluid channel with Fig.19 The sector plate 2200 may be printed via a 3D printer, such as Figure 6 Printer 600.

[0123] In the example shown, the sector plate 2200 has a first radial edge 2202 forming a first mating feature 2204 and a second radial edge 2206 forming a second mating feature 2208 complementary to the first mating feature 2204. In this example, the first mating feature 2204 is a V-shaped wedge and the second mating feature 2208 is a V-shaped groove. When four sector plates 2200 are assembled into a disk-shaped plate, the first mating feature 2204 of each sector plate 2200 engages or mates with the second mating feature 2208 of an adjacent sector plate 2200. Therefore, each sector plate 2200 overlaps two adjacent sector plates 2200 in the axial direction. This mating design prevents the sector plates 2200 from being axially displaced or moved under the high pressure of the fluid flow.

[0124] In the example shown, the fan plate 2200 has a first wall 2210 forming a first side of the fan plate 2200 and a second wall 2212 forming a second side of the fan plate 2200. The fan plate 220 has a first plurality of openings 2214 extending between the first wall 2210 and the second wall 2212 (one of which is located at Fig. 22 Openings 2214 form a flow path through sector plate 2200 to attenuate noise.

[0125] In some examples, the sector plate 2200 is substantially solid, and the opening 2214 extends through the body of the sector plate 2200. For example, Fig.23 An example of a sector plate 2200 is shown cut along a center plane of the sector plate 2200. In this example, the inner body of the sector plate 2200 is substantially solid, and the openings 2214 (one of which is in Fig.23 ) extends through the solid body.

[0126] In other examples, the inner body of the sector plate 2200 may be partially hollow or include other structures, such as a lattice structure. Fig.24Another cross-sectional version of the sector plate 2200 is shown. In this example, the interior of the sector plate 2200 has an internal lattice structure 2400. The internal lattice structure forms a plurality of openings 2402 (one of which is located at Fig.24 ). In this example, opening 2402 is diamond-shaped. In some examples, this diamond-shaped lattice structure allows easier printing in the vertical direction by limiting wall overhang. In other examples, the internal lattice structure 2400 can form openings of different shapes (e.g., squares, triangles, hexagons, octagons, etc.). Fig.25 yes Fig.24 A top view of the sector plate 2200, Fig.24 An internal lattice structure 2400 and an opening 2402 are shown. The opening 2402 fluidly connects an opening in the first wall 2210 to a second wall 2212 ( Fig. 22 ). In the example shown, the openings 2402 of the internal lattice structure 2400 are larger than the openings in the first wall 2210 and the openings in the second wall 2212. Thus, each of the openings 2402 of the internal lattice structure 2400 fluidly connects a plurality of openings in the first wall 2210 and a plurality of openings in the second wall 2212.

[0127] Fig.26 is a side cross-sectional view of the sector plate 2200, showing an opening 2402 of the internal lattice structure 2400. The first wall 2210 has a first plurality of openings 2600 (three of which are in Fig.26 ) and the second wall 2212 has a second plurality of openings 2602 (three of which are in Fig.26 ). The openings 2402 of the internal lattice structure 2400 fluidly connect a set of first plurality of openings 2600 and a set of second plurality of openings 2602. In some examples, the internal lattice structure 2400 is formed to pass through the entire sector plate 2200, including the portion where the first mating feature 2204 and the second mating feature 2208 are formed. In other examples, the internal lattice structure 2400 is formed only in the center or main portion of the sector plate 2200, and the portion where the first mating feature 2204 and the second mating feature 2208 are formed does not include the internal lattice structure.

[0128] The example internal lattice structure 2400 reduces the amount of material used to construct the sector plate 2200. In other words, the sector plate 2200 contains less material than a sector plate with a solid internal structure. In this way, the manufacturing cost of the sector plate 2200 is lower and results in a lighter disc plate. As described above, the sector plate 2200 can be constructed by a 3D printer. The internal lattice structure 2400 can be formed during the 3D printing process. Such an internal lattice structure may not be achievable via traditional (subtractive) machining processes.

[0129] Furthermore, with this design, the first wall 2210 and the second wall 2212 effectively form two attenuator panels. For example, the first wall 2210 has a first plurality of openings 2600 and the second wall 2212 has a second plurality of openings 2602. Thus, this design results in two flow stages (double expansion), which further improves the noise attenuation performance of the sector panel 2200. The first wall 2210 and the second wall 2212 can be thinner or thicker, depending on the structural load requirements.

[0130] In some examples, instead of having an internal lattice structure, the internal cross-section of the sector plate can be completely hollow. In some examples, one or more portions of the disc plate can include a hollow cross-section or lattice structure, while one or more other portions can be solid. In another example, the entire sector plate can be a lattice structure without using side walls. In such an example, the flow path has a constant cross-section across the thickness of the plate, as defined by the lattice geometry. It should be understood that any example disc plate and / or individual sector plate disclosed herein can include an internal lattice structure or a variation thereof disclosed in conjunction with the example.

[0131] Fig. 27 2 is a perspective view of an example disk-shaped plate 2700 formed by a fan-shaped plate 2200 (also referred to herein as a first fan-shaped plate 2200) and three other fan-shaped plates 2704-2708 (referred to as a second fan-shaped plate, a third fan-shaped plate, and a fourth fan-shaped plate 2704-2708). The second fan-shaped plate, the third fan-shaped plate, and the fourth fan-shaped plate are identical to the first fan-shaped plate 2200 (i.e., have the same size and shape) and can also be printed by a 3D printer, such as Figure 6 3D printer 600. The disc-shaped plate 2700 may be disposed in the fluid channel with Fig.19 The disc-shaped plate 1700 shown in FIG.

[0132] When the sector plates 2200, 2704-2708 are assembled into the disc plate 2700, the first mating features 2204 ( Figure 2 ) with a second mating feature 2208 ( Figure 2 ) engagement or mating. Thus, each of the sector plates 2200, 2704-2708 overlaps two adjacent sector plates 2200, 2704-2708 in the axial direction. This mating design prevents the sector plates 2702-2708 from axially shifting or moving under high pressure of fluid flow from the upstream or downstream direction. Due to the V-shaped overlap, in this example, an isolated point force will not cause one of the sector plates 2200, 2704-2708 to rotate or twist. The mating features 2204, 2208 ( Fig. 22)'s internal locking design prevents twisting in two directions (radial outward torque and radial inward torque), thereby preventing folding between sector plates 2200, 2704-2708.

[0133] Fig.28A , Fig.28B , Fig.28C and Fig.28D The assembly of the sector plates 2200, 2704-2708 to the disk plate 2700 ( Fig.28D ) in an example sequence. The sector plates 2200, 2704-2708 can be placed radially apart on a flat surface. Then, the sector plates 2200, 2704-2708 can be pushed radially inward until all the sector plates 2200, 2704-2708 are mated.

[0134] In some examples, each of the sector plates 2200, 2704-2708 may include an internal lattice structure, such as a combination of Figure 24-26 In other examples, the sector plates 2200, 2704-2708 may not include an internal lattice structure. Fig.23 As disclosed, the openings may extend straight through the respective sector plates 2200, 2704-2708. For example, Fig.29 A cross-sectional view of an example disk-shaped plate 2700 is shown, wherein the disk-shaped plate 2700 does not include an internal lattice structure. Instead, the openings 2214 extend through the solid internal structure of the disk-shaped plate 2700.

[0135] In some examples, the opening 2214 is located adjacent to the first mating feature 2204 and the second mating feature 2208 ( Fig. 22 ) of the interface of the fan-shaped plate 2200, 2704-2708 is omitted. In some examples, the interface is relatively thin. For example, Fig.29 As shown, first portion 2900 along second radial edge 2206 of first sector plate 2200 does not include an opening. In addition, second portion 2902 does not include an opening. Second portion 3202 corresponds to the radial edge that forms the first mating feature of second sector plate 2704. In other examples, one or more of these portions may still have an opening.

[0136] For example, Fig.30 is a perspective view of another example disc-shaped plate 3000. The disc-shaped plate 3000 is substantially the same as the disc-shaped plate 2700 disclosed above. However, in this example, the disc-shaped plate 3000 does not include the portion 2902 where the opening is omitted. Fig.31 The disc-shaped plate 3000 is shown with the first wall removed.

[0137] Figure 32-Figure 43Example disc-shaped plates with various shaped mating features are shown. The function of the mating features is essentially the same as in the above examples, to prevent or reduce axial displacement of the sector plate. In some examples, the mating features overlap not only in the axial direction, but also in the circumferential direction. Therefore, engagement may occur in a specific direction.

[0138] The openings through the disc plates are not Figure 32-Figure 43 However, it is understood that Figure 32-Figure 43 The disc-shaped plates may include a plurality of openings extending through the respective disc-shaped plates. Figure 32-Figure 43 Any of the disk-shaped plates may include an internal lattice structure, similar to the internal lattice structure in the examples disclosed above. Each of the disk-shaped plates is formed by a plurality of sector plates. Any number of sector plates may be used. The sector plates may be printed in a 3D printer, for example Figure 6 3D printer 600. Some Figure 32-Figure 43 The disc-shaped plate is more suitable for machining operations due to its complex printing. Figure 32-Figure 43 Any disc-shaped plate can be arranged in the fluid channel with Fig.19 The disc-shaped plate 1700 shown in FIG.

[0139] In some examples, such as in Fig.42 and Fig.43 In the embodiment, the sector plate overlaps the other two sector plates at the mating features in the axial direction. In other examples, the sector plate can be designed so that the sector plate overlaps the other sector plates of more than two other sector plates at the mating features in the axial direction. In some examples, for example, Fig.37 and Fig.43 In the embodiment of the present invention, the disc-shaped plate can have a groove or opening in the center. The groove or opening can be used to receive a support member, such as a center rod. In some examples, the disc-shaped plate can include additional openings to receive other support rods for supporting the disc-shaped plate. If support rods or spacers are used, the disc-shaped plate can have completely solid areas or areas with thicker walls.

[0140] Fig.44 4400 is a flow chart showing an example method 4400 of manufacturing a disk-shaped plate and installing the disk-shaped plate in a fluid body. Fig.17 The example method 4400 is described with reference to the disk-shaped plate 1700 of FIG. However, it should be understood that the example method 4400 may be similarly performed in conjunction with any of the example disk-shaped plates disclosed herein.

[0141] At block 4402, the example method 4400 includes printing a plurality of sector plates via a 3D printer. For example, the sector plates 1702-1708 may be printed via a 3D printer, such as Figure 63D printer 600. In some examples, each of the fan-shaped plates 1702-1708 is printed in a vertical direction. This allows multiple fan-shaped plates to be printed side by side in the same print batch. The fan-shaped plates 1702-1708 can be printed simultaneously as part of the same print batch or printed at different times. In some examples, one or more post-processing operations (e.g., drilling, cutting, grinding, etc.) can be performed to smooth the surface of the fan-shaped plates 1702-1708. Each of the fan-shaped plates 1702-1708 includes a first mating feature 1804 and a second mating feature 1806 that is complementary to the first mating feature 1804. The fan-shaped plates 1702-1708 include an opening 1710. In some examples, the fan-shaped plates 1702-1708 may include an internal lattice structure.

[0142] At block 4404, the example method 4400 includes assembling the sector plates into a disc-shaped plate. For example, the sector plates 1702-1708 may be placed radially spaced apart on a flat surface and then moved radially inward toward each other. The mating features engage or mate with corresponding mating features of adjacent sector plates 1702-1708.

[0143] At block 4406, the example method 4400 includes coupling a disk-shaped plate to a fluid body such that the disk-shaped plate is disposed in a fluid channel of the fluid body. Fig.19 As shown, the disc-shaped plate 1700 is disposed in the fluid passage 1904 of the body 1902 of the noise attenuator 1900. In some examples, the disc-shaped plate 1700 is coupled to the body 1902 by clamping the peripheral region of the disc-shaped plate 1700 between the body 1902 and the downstream tube 1916. This clamping locks the peripheral region of the disc-shaped plate 1700 in place. In addition, the mating design prevents or reduces axial displacement of the sector plates 1702-1708. Thus, in some examples, the method 4400 does not include using threaded fasteners or support structures to construct the disc-shaped plate 1700 or couple the disc-shaped plate 1700 to the body 1902. However, in other examples, fasteners or support structures may be used.

[0144] While in many of the examples disclosed herein, the disc-shaped plate is coupled to or otherwise integrated with the body of the noise attenuator, any of the example plates and / or plate assemblies disclosed herein may alternatively be directly coupled to or integrated into the body of a process control device that generates the audible noise. For example, the disc-shaped plate may be coupled to the outlet of a regulating valve or a valve to attenuate the noise of fluid exiting the regulating valve or the valve.

[0145] Any of the example plates and / or plate assemblies disclosed herein may also be implemented in other devices using multipath flow plates, such as flame arresters. In flame arrester applications, the size of the flow paths may be determined based on the process gas use specific maximum experimental safe gap (MESG) or aperture. In some examples, identical plates may be stacked according to operating parameters. In some examples, plates with the same cross-section may be 3D printed taller or shallower, depending on the application and / or media.

[0146] The example interlocking plate designs disclosed herein can also be used in other applications that are not related to controlling the flow of fluids through the plates. For example, many valves and other flow control devices have an opening on the top that is sealed with a cover plate. For example, if the valve needs maintenance, the cover plate can be removed to access the internal portions of the valve. The cover plate is typically a large plate with a flange that extends beyond the size of the opening so that the flange can be bolted to a corresponding flange on the valve body or to a cover covering the cover plate. In contrast, an example disc-shaped plate formed by multiple sector plates with mating features can be used. In such an example, the sector plates would not have a flow path opening, but instead could be completely solid. For example, the inner diameter of the opening in the valve body could have a recess, similar to Fig.19 The recess 1918 shown in the outlet 1908 of the main body 1902 can be formed, and multiple sector plates can be arranged into a disc plate and inserted into the recess. The peripheral area of ​​the disc plate can then be clamped or fixed to the valve body using a retaining ring or cross plate. In this way, the disc plate can be used as a cover to cover or seal the opening. Such a disc plate with multiple sector plates may be easier to install and remove than a traditional cover plate. In addition, this will enable larger plates to be built via 3D printing, which is advantageous because it can be used to create complex features in the sector plates.

[0147] Although in many examples disclosed herein, the disk-shaped plate is formed by a plurality of sector-shaped plates, in other examples, any example disk-shaped plate can be formed by one or more plate portions that are not sector-shaped. For example, the disk-shaped plate can be formed by a plurality of strips that form the disk-shaped plate when arranged adjacent to each other. In another example, the disk-shaped plate can be formed by a center piece surrounded by radial portions.

[0148] "Include" and "comprising" (and all their forms and tenses) are used herein as open-ended terms. Thus, whenever a claim adopts any form of "include" or "comprising" (e.g., includes, comprises, includes, including, having, etc.) as a preamble or in any type of claim statement, it should be understood that additional elements, terms, etc. may be present without exceeding the scope of the corresponding claim or statement. As used herein, when the phrase "at least" is used as a transitional term, such as in the preamble of a claim, it is open-ended in the same manner as the terms "include" and "comprising". The term "and / or" when used in the form of, for example, A, B, and / or C, refers to any combination or subset of A, B, and C, such as (1) A alone, (2) B alone, (3) C alone, (4) A and B, (5) A and C, (6) B and C, and (7) A and B and C. As used herein in the context of describing structures, components, items, objects, and / or things, the phrase "at least one of A and B" is intended to refer to embodiments that include (1) at least one A, (2) at least one B, and (3) at least one A and at least one B. Similarly, as used herein in the context of describing structures, components, items, objects, and / or things, the phrase "at least one of A or B" is intended to refer to embodiments that include any of (1) at least one A, (2) at least one B, and (3) at least one A and at least one B. As used herein in the context of describing the execution or performance of processes, instructions, actions, activities, and / or steps, the phrase "at least one of A and B" is intended to refer to embodiments that include any of (1) at least one A, (2) at least one B, and (3) at least one A and at least one B. Similarly, as used herein in the context of describing the execution or performance of processes, instructions, actions, activities, and / or steps, the phrase "at least one of A or B" is intended to refer to embodiments that include any of (1) at least one A, (2) at least one B, and (3) at least one A and at least one B.

[0149] As used herein, singular references (e.g., "a," "an," "first," "second," etc.) do not exclude the plural. As used herein, the term "a" or "an" entity refers to one or more of that entity. The terms "a" (or "an"), "one or more," and "at least one" are used interchangeably herein. In addition, although listed separately, multiple devices, elements, or method actions may be implemented by, for example, a single unit or processor. In addition, although individual features may be included in different examples or claims, these may potentially be combined, and the inclusion in different examples or claims does not mean that the combination of features is not feasible and / or not advantageous.

[0150] As can be understood from the above, example multi-channel plates have been disclosed, which can be advantageously used in devices such as noise attenuators and flame arresters. Some examples disclosed herein utilize a support frame to support the plate, which enables the use of relatively thin plates. Relative to thicker plates, thin plates have reduced friction losses. Thin plates are also easier to manufacture and less expensive. An example plate formed by a plurality of matching or interlocking sector plates is also disclosed, and therefore no fasteners or support structures are required. The example plates disclosed herein can be constructed via 3D printing, which is generally more efficient than known machining processes and results in less material waste. In addition, 3D printing can also form complex mating features, relatively small openings, and lattice structures, which are generally not feasible in traditional machining processes.

[0151] Example methods, devices, systems, and articles have been disclosed. Different aspects of the examples disclosed herein can be combined in other examples. Other examples and combinations thereof include the following.

[0152] Example 1 is a plate assembly for a noise attenuator. The plate assembly includes a support frame to be coupled to a body of the noise attenuator. The support frame has a plurality of radially extending ribs. The plate assembly also includes a disc-shaped plate having a plurality of openings that form a flow path to attenuate noise. The disc-shaped plate is coupled to the support frame so that a load caused by pressure on the disc-shaped plate is distributed to the plurality of radially extending ribs of the support frame.

[0153] Example 2 includes the plate assembly of Example 1, wherein the disc-shaped plate is formed by a plurality of sector plates coupled to a support frame. A plurality of openings are formed in the plurality of sector plates.

[0154] Example 3 includes the plate assembly of Example 2, wherein each sector plate of the plurality of sector plates has the same shape and size.

[0155] Example 4 includes the plate assembly of Example 2 or 3, wherein each of the plurality of sector plates is constructed via a layer of molten material.

[0156] Example 5 includes the plate assembly of any of Examples 2-4, wherein the plurality of openings are teardrop-shaped.

[0157] Example 6 includes the panel assembly of any of Examples 2-5, wherein the plurality of sector panels are coupled to the support frame via threaded fasteners.

[0158] Example 7 includes the panel assembly of Example 6, wherein at least one of the threaded fasteners couples two of the plurality of sector panels to the support frame.

[0159] Example 8 includes the panel assembly of any of Examples 1-7, wherein the plurality of openings is a first plurality of openings, and wherein the support frame has a second plurality of openings having a larger cross-sectional area than the first plurality of openings.

[0160] Example 9 includes the plate assembly of Example 8, wherein the support frame has a plurality of rings, and wherein the second plurality of openings is formed by an arrangement of a plurality of radially extending ribs and the plurality of rings.

[0161] Example 10 includes the plate assembly of Example 8 or 9, wherein the first plurality of openings are arranged in groups aligned with the second plurality of openings.

[0162] Example 11 is a noise attenuator, comprising a body defining a fluid passage between an inlet and an outlet and a plate assembly coupled to the body. The plate assembly comprises a disc-shaped plate disposed in the fluid passage. The disc-shaped plate has a plurality of openings forming a flow path. The plate assembly further comprises a support frame disposed downstream of the disc-shaped plate so that a load caused by pressure on the disc-shaped plate is distributed to the support frame.

[0163] Example 12 includes the noise attenuator of Example 11, wherein the plate assembly is coupled to the body at or near the outlet.

[0164] Example 13 includes the noise attenuator of Example 12, wherein the support frame has a flange configured to be coupled between an outlet flange of the body and an inlet flange of the downstream conduit.

[0165] Example 14 includes the noise attenuator of any of Examples 11-13, wherein the disk-shaped plate is formed by a plurality of sector-shaped plates.

[0166] Example 15 includes the noise attenuator of Example 14, wherein the plurality of sector panels are coupled to a support frame.

[0167] Example 16 is a method comprising printing a plurality of sector plates via a three-dimensional (3D) printer. The plurality of sector plates have a plurality of openings forming a flow path. The plurality of sector plates, when arranged together, form a disc-shaped plate to be disposed in a fluid to affect the flow of the fluid through a fluid body.

[0168] Example 17 includes the method of Example 16, wherein each sector plate of the plurality of sectors plates is printed in a vertical orientation.

[0169] Example 18 includes the method of Example 16 or 17, further comprising coupling a plurality of sector plates to the support frame. The plurality of sector plates form a disk-shaped plate when coupled to the support frame.

[0170] Example 19 includes the method of Example 18, further comprising coupling the support frame to the fluid body such that the disk-shaped plate is disposed in a fluid channel of the fluid body.

[0171] Example 20 includes the method of Example 19, further comprising coupling a support frame to the fluid body such that the support frame is disposed downstream of the disc-shaped plate.

[0172] Example 21 is a disc-shaped plate for a noise attenuator. The disc-shaped plate includes a plurality of sector plates. The plurality of sector plates have openings defining a flow path. Each of the plurality of sector plates has a first radial edge forming a first mating feature and a second radial edge forming a second mating feature complementary to the first mating feature, so that when the plurality of sector plates are arranged together, the first mating feature of each of the plurality of sector plates is mated with the second mating feature of an adjacent one of the plurality of sector plates.

[0173] Example 22 includes the disk-shaped plate of Example 21, wherein each of the plurality of sector plates has the same shape and size.

[0174] Example 23 includes the disk-shaped plate of Example 21 or 22, wherein when the plurality of sector plates are arranged together, a portion of each of the plurality of sector plates overlaps an adjacent one of the plurality of sector plates in an axial direction.

[0175] Example 24 includes the disk-shaped plate of any of Examples 21-23, wherein each of the plurality of sector-shaped plates is constructed via a layer of molten material.

[0176] Example 25 includes the disc-shaped plate of any of Examples 21-24, wherein the opening is teardrop-shaped.

[0177] Example 26 includes the disc-shaped plate of any of Examples 21-25, wherein the plurality of sector plates includes a first sector plate. The first sector plate includes a first wall forming a first side of the first sector plate, a second wall forming a second side of the first sector plate, and an internal lattice structure between the first wall and the second wall, the first wall having a first plurality of openings, and the second wall having a second plurality of openings.

[0178] Example 27 includes the disk-shaped plate of Example 26, wherein the internal lattice structure forms a third plurality of openings.

[0179] Example 28 includes the disk-shaped plate of Example 27, wherein an opening in the third plurality of openings is fluidly connected to a first plurality of first openings in the first wall and a second plurality of second openings in the second wall.

[0180] Example 29 includes the disk-shaped plate of Example 27 or 28, wherein the third plurality of openings are diamond-shaped.

[0181] Example 30 includes the disk-shaped plate of Examples 21-29, wherein the plurality of sector plates are not coupled by fasteners.

[0182] Example 31 is a noise attenuator, which includes a body defining a fluid passage between an inlet and an outlet and a disc-shaped plate disposed in the fluid passage. The disc-shaped plate has a plurality of openings that form a flow path for reducing noise of fluid flowing in the fluid passage. The disc-shaped plate is formed by a plurality of sector plates having mating features so that when the plurality of sector plates are arranged together, a portion of each of the plurality of sector plates overlaps with an adjacent one of the plurality of sector plates in an axial direction.

[0183] Example 32 includes the noise attenuator of Example 31, wherein the disc-shaped plate is disposed at or near an outlet in the fluid passage.

[0184] Example 33 includes the noise attenuator of Example 32, wherein the peripheral region of the disc-shaped plate is configured to be sandwiched between an outlet flange of the body and an inlet flange of the downstream conduit.

[0185] Example 34 includes the noise attenuator of any of Examples 31-33, wherein the plurality of sector plates are not coupled by fasteners.

[0186] Example 35 includes the noise attenuator of any of Examples 31-34, further comprising an additional plate disposed in the fluid passage upstream of the disc-shaped plate.

[0187] Example 36 is a method comprising printing a plurality of sector plates via a three-dimensional (3D) printer. The plurality of sector plates have openings defining a flow path. Each of the plurality of sector plates has a first radial edge forming a first mating feature and a second radial edge forming a second mating feature complementary to the first mating feature.

[0188] Example 37 includes the method of Example 36, wherein the plurality of sector plates are printed by the 3D printer during the same print batch.

[0189] Example 38 includes the method of Example 36 or 37, further comprising assembling a plurality of sector plates to form a disk-shaped plate.

[0190] Example 39 includes the method of Example 38, further comprising coupling the disk-shaped plate to the fluid body such that the disk-shaped plate is disposed in a fluid channel of the fluid body.

[0191] Example 40 includes the method of Example 39, wherein an outer peripheral region of the disc-shaped plate is sandwiched between the body of fluid and the downstream conduit.

[0192] Although certain example methods, apparatus, and articles have been disclosed herein, the scope of coverage of this patent is not limited thereto. Instead, this patent covers all methods, apparatus, and articles that fully fall within the scope of the claims of this patent.

[0193] The following claims are incorporated into the Detailed Description by reference, with each claim standing on its own as a separate embodiment of the present disclosure.

Claims

1. A plate assembly for a noise attenuator, the plate assembly comprising: a support frame to be coupled to a body of the noise attenuator, the support frame having a plurality of radially extending ribs; as well as a disk-shaped plate having a plurality of openings forming a flow path to attenuate noise, the disk-shaped plate being coupled to the support frame such that a pressure-induced load on the disk-shaped plate is distributed to the plurality of radially extending ribs of the support frame, The disc-shaped plate is formed by a plurality of sector plates coupled to the support frame, the plurality of openings are formed in the plurality of sector plates, each of the plurality of sector plates has a first radial edge, a second radial edge and a peripheral edge, and the plurality of sector plates are arranged so that the first radial edge of each of the plurality of sector plates is arranged along the second radial edge of an adjacent one of the plurality of sector plates to form the disc-shaped plate.

2. The panel assembly of claim 1, wherein each of the plurality of sector panels has the same shape and size.

3. The plate assembly of claim 1, wherein each sector plate of the plurality of sector plates is constructed by a layer of molten material.

4. The plate assembly of claim 1, wherein the plurality of openings are teardrop shaped.

5. The panel assembly of claim 1, wherein the plurality of sector panels are coupled to the support frame by threaded fasteners.

6. The panel assembly of claim 5, wherein at least one of the threaded fasteners couples two of the plurality of sector panels to the support frame.

7. The panel assembly of claim 1, wherein the plurality of openings is a first plurality of openings, and wherein the support frame has a second plurality of openings, the second plurality of openings having a larger cross-sectional area than the first plurality of openings.

8. The panel assembly of claim 7, wherein the support frame has a plurality of rings, and wherein the second plurality of openings are formed by an arrangement of the plurality of radially extending ribs and the plurality of rings.

9. The plate assembly of claim 7, wherein the first plurality of openings are arranged in groups aligned with the second plurality of openings.

10. The plate assembly of claim 8, wherein the first plurality of openings are arranged in groups so as to be aligned with the second plurality of openings, and wherein the disc-shaped plate has solid portions between adjacent groups of the groups of the first plurality of openings, the solid portions being aligned with the radially extending plurality of ribs and the plurality of rings of the support frame.

11. The plate assembly of claim 10, wherein the solid portion of the disc-shaped plate forms a shape that matches a shape formed by the plurality of radially extending ribs and the plurality of rings of the support frame.

12. A noise attenuator comprising: a body defining a fluid passage between the inlet and the outlet; as well as The plate assembly of claim 1, wherein the plate assembly is coupled to the body.

13. The noise attenuator of claim 12, wherein the plate assembly is coupled to the body at a location closer to the outlet than to the inlet.

14. The noise attenuator of claim 13, wherein the support frame has a flange configured to be coupled between an outlet flange of the body and an inlet flange of a downstream conduit.

15. A method for making a plate assembly for a noise attenuator, comprising: Printing a plurality of sector plates by a three-dimensional (3D) printer, the plurality of sector plates having a plurality of openings forming a flow path, each of the sector plates having a first radial edge, a second radial edge, and a peripheral edge, wherein the plurality of sector plates are arranged together such that the first radial edge of each of the plurality of sector plates is arranged along the second radial edge of an adjacent one of the plurality of sector plates to form a disc-shaped plate to be arranged in a fluid body to affect a fluid flow through the fluid body; and The plurality of sector plates are coupled to a support frame, the plurality of sector plates forming the disc-shaped plate when coupled to the support frame, the support frame being coupled to the fluid body, the support frame having a plurality of radially extending ribs such that a load caused by pressure on the disc-shaped plate is distributed to the extending plurality of ribs.

16. The method of claim 15, wherein each of the plurality of sector plates is printed in a vertical direction.

17. The method according to claim 15, further comprising: The support frame is coupled to the fluid body such that the disc-shaped plate is disposed in a fluid channel of the fluid body.

18. The method according to claim 17, further comprising: A support frame is coupled to the fluid body such that the support frame is disposed downstream of the disc-shaped plate.

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