Panel and panel assembly for noise attenuators and other devices and method of manufacture

Abstract

Described herein are plates and plate assemblies for noise attenuators and other devices and methods of manufacturing the same. Example disc-shaped plates described herein include a plurality of sector-shaped plates having openings defining flow paths. Each sector-shaped plate of the plurality of sector-shaped 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, such that when the plurality of sector-shaped plates are arranged together, the first mating feature of each sector-shaped plate of the plurality of sector-shaped plates mates with the second mating feature of an adjacent one of the plurality of sector-shaped plates.

Description

TECHNICAL FIELD

[0001] The present disclosure relates generally to noise attenuators, and more particularly, to plates and plate assemblies for noise attenuators and other devices and methods of manufacturing the same. BACKGROUND

[0002] Fluid valves, regulating valves, and other process control devices are often distributed throughout a 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 characteristics of the fluid, such as pressure, temperature, flow rate, etc. Such changes in fluid characteristics often result in a significant amount of audible noise. For example, fluid regulating valves are often used to reduce and / or regulate fluid pressure to a predetermined value. Some fluid regulating valves reduce an inlet pressure to a lower outlet pressure by restricting the flow through an orifice to match downstream demand. However, the fluid flowing through the pressure regulating valve creates a significant amount of audible noise. Therefore, a noise attenuator is often coupled to the outlet of the pressure regulating valve. Known noise attenuators include a series of plates having small openings that form flow passages through the plates. SUMMARY

[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 such that a pressure-induced load on the disc-shaped plate is distributed to the plurality of radially extending ribs of the support frame.

[0004] A 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 that form a flow path. The plate assembly also includes a support frame disposed downstream of the disc-shaped plate such that a pressure-induced load on the disc-shaped plate is distributed to the support frame.

[0005] A method disclosed herein includes printing a plurality of sector-shaped plates via a three-dimensional (3D) printer. The plurality of sector-shaped plates has a plurality of openings that form a flow path. The plurality of sector-shaped plates form a disc-shaped plate when arranged together to be disposed in a fluid body to affect flow of a fluid through the fluid body.

[0006] A disc-shaped plate for a noise attenuator disclosed herein includes a plurality of sector-shaped plates. The plurality of sector-shaped plates have openings that define flow paths. Each of the plurality of sector-shaped 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, such that when the plurality of sector-shaped plates are arranged together, the first mating feature of each of the plurality of sector-shaped plates mates with the second mating feature of an adjacent one of the plurality of sector-shaped plates.

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

[0008] A method disclosed herein includes printing a plurality of sector-shaped plates via a three-dimensional (3D) printer. The plurality of sector-shaped plates have openings that define flow paths. Each of the plurality of sector-shaped 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. BRIEF DESCRIPTION OF DRAWINGS

[0009] FIG. 1 is a side view of an example regulator valve assembly including an example noise attenuator in which example plates and example plate assemblies disclosed herein can be implemented.

[0010] FIG. 2 is a perspective view of an example noise attenuator of FIG. 1 including an example plate assembly.

[0011] FIG. 3 is a perspective view of an example plate assembly of FIG. 2 including a support frame and a disc-shaped plate formed by a plurality of sector-shaped plates.

[0012] FIG. 4 is a perspective view of an example plate assembly of FIG. 3 showing only one of the sector-shaped plates.

[0013] FIG. 5 is a cross-sectional view of one of the sector-shaped plates and FIG. 3 the support frame of

[0014] FIG. 6 shows an example three-dimensional (3D) printer that can be used to print the sector-shaped plates of FIG. 3 .

[0015] FIG. 7A is a close-up view of an example opening formed in one of the example sector plates by a 3D printer of FIG. 6

[0016] FIG. 7B is a close-up view of another example opening formed in one of the example sector plates by a 3D printer of FIG. 6

[0017] FIG. 8 is a perspective view of an example support frame of an example plate assembly of FIG. 3

[0018] FIG. 9 is an end view of another example support frame that can be used with an example disc-shaped plate of FIG. 3

[0019] FIG. 10 is a perspective view of another example support frame that can be used with an example disc-shaped plate of FIG. 3

[0020] FIG. 11 is an end view of another example support frame that can be used with an example disc-shaped plate of FIG. 3

[0021] FIG. 12 is a perspective view of an example housing having a plurality of example plate assemblies that can be implemented in a noise attenuator.

[0022] FIG. 13 is another perspective view of an example housing of FIG. 12

[0023] FIG. 14 is an end view of an example housing of FIG. 13

[0024] FIG. 15 is a side view of an example housing of FIG. 12

[0025] FIG. 16 is a flowchart representing an example method of manufacturing an example disc-shaped plate and installing the example disc-shaped plate in a fluid body.

[0026] FIG. 17 is a perspective view of an example disc-shaped plate formed by a plurality of example sector plates that can be implemented in a noise attenuator.

[0027] FIG. 18 is an exploded view of an example disc-shaped plate of FIG. 17

[0028] FIG. 19 is a perspective cross-sectional view of an example noise attenuator, wherein​​​​​​​​​​A perspective view of an example sector plate of the example sector plates of FIG. 17 is implemented in the example noise attenuator.

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

[0030] FIG. 21 is FIG. 20 Another perspective view of the example sector plate of

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

[0032] FIG. 23 is FIG. 22 A perspective cross-sectional view of the example sector plate of

[0033] FIG. 24 is FIG. 22 A perspective cross-sectional view of the example sector plate of

[0034] FIG. 25 is FIG. 24 A top view of the example sector plate of

[0035] FIG. 26 is FIG. 24 A side cross-sectional view of the example sector plate of

[0036] FIG. 27 is a perspective view of an example disc-shaped plate formed by a plurality of example sector plates corresponding to FIG. 22

[0037] FIG. 28A-28D shows an example sequence of assembling a plurality of example sector plates to form an example disc-shaped plate of FIG. 27

[0038] FIG. 29 is a perspective cross-sectional view of an example disc-shaped plate of FIG. 27 showing an example opening extending through the example disc-shaped plate.

[0039] FIG. 30 is a perspective view of an example disc-shaped plate that can be implemented in a noise attenuator formed by a plurality of example sector plates.

[0040] FIG. 31 shows an example disc-shaped plate of FIG. 30 with a first side removed.

[0041] ​FIG. 32 to FIG. 43 is a perspective view of an example disc-shaped panel of sector-shaped panels having various shapes that can be implemented in a noise attenuator.

[0042] FIG. 44 is a flowchart representing an example method of manufacturing an example disc-shaped panel and installing the example disc-shaped panel in a fluid body.

[0043] The drawings are not to scale. Instead, thickness of layers or regions can be exaggerated in the drawings for the sake of clarity. Generally, the same reference numbers will be used throughout the drawings and accompanying written description to refer to the same or like parts. As used in this patent, to say that any part (e.g., layer, film, zone, region, or panel) is on (e.g., positioned on, located on, disposed on, or formed on, etc.) another part means that the referenced part is in contact with the other part, or that the referenced part is above the other part and one or more intervening parts are between them. Unless otherwise stated, a connecting reference (e.g., attached, coupled, connected, and bonded) should be construed broadly and can include intervening members between the elements of a set and relative movement between the elements. Thus, a connecting reference does not necessarily infer that two elements are directly connected and in fixed relation to one another. To say that any part is in “contact” with another part means that there are no intervening parts between the two parts.

[0044] When identifying multiple elements or components that can be individually referenced, the descriptors “first,” “second,” “third,” etc. are used herein. Unless otherwise stated or understood from the context of their use, such descriptors are not intended to impart any meaning of priority, physical order or arrangement, or temporal ordering in a list, but are merely used as labels to refer to multiple elements or components, respectively, for ease of understanding the disclosed examples. In some examples, the descriptor “first” can be used to refer to an element in the detailed description, while a different descriptor 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 ease of referencing multiple elements or components. DETAILED DESCRIPTION

[0045] Many known process control and / or fluid distribution systems (e.g., power generation systems, oil refinery systems, natural gas distribution plants, fuel storage tanks, etc.) employ 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 that receives fluid from a source at a relatively high pressure and an outlet that provides the fluid to a downstream device at a relatively lower pressure than the inlet. The inlet pressure of some known pressure regulating valves is reduced to the lower outlet pressure by restricting the flow through an orifice to match downstream demand. For example, known pressure regulating valves of process control and / or fluid distribution systems receive fluid (e.g., gas, liquid) from an upstream source having a relatively high and somewhat variable pressure and regulate the fluid flow to reduce and / or stabilize the pressure to a level suitable for use by downstream devices (e.g., devices of power generators, oil refineries, etc.).

[0046] In some cases, process control devices affect the flow of fluids in a manner that produces audible noise. For example, pressure regulating valves 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 significant amounts of audible noise. Accordingly, 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 devices.

[0047] Disclosed herein are example noise attenuators. The noise attenuators include one or more plates or discs disposed in a fluid passage to induce a pressure drop along a flow path through the fluid passage. The plates include openings (e.g., holes, apertures) that define a flow path of fluid through the plates and thus through the fluid passage. As the fluid passes through the plates, the pressure of the fluid gradually decreases along the flow path (e.g., by a discrete amount, by a percentage of the previous fluid pressure). The pressure drop induced by the plates achieves a corresponding reduction or attenuation of noise (e.g., by a discrete decibel level, by a percentage of the decibel level produced by the pressure regulating valve).

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

[0049] Accordingly, some known panels are relatively thick to withstand the structural load requirements caused by pressure drop. However, because known thick panels are typically machined from large, thick sheets of metal that are cut into individual panels and drilled (perforated), these known thick panels are difficult and costly to manufacture. Moreover, these known thick panels significantly increase the weight of the noise attenuator, which can complicate shipping, assembly, and installation. Other known panels use a central rod that connects and supports the center of the panel. However, this type of support is prone to bending around the peripheral portions of the panel (sometimes referred to as a taco effect). Accordingly, the panel still needs to be relatively thick to withstand these forces without exhibiting any significant bending. Moreover, the traditional machining operations used to produce these known panels are limited in feature density (e.g., the number and size of flow paths that can be formed in a panel in a given area).

[0050] Disclosed herein are example panel assemblies that include a thin disc-shaped panel and a support frame for supporting the disc-shaped panel and providing rigidity to the disc-shaped panel. The disc-shaped panel can be coupled (e.g., via one or more threaded fasteners) to the support frame, and the support frame can be coupled (e.g., via one or more threaded fasteners) to a main body of an attenuator such that the disc-shaped panel is disposed in a fluid passage of the attenuator main body. The support frame is disposed downstream of the disc-shaped panel such that pressure-induced loads on the disc-shaped panel are distributed to the support frame. In this way, the support frame prevents or reduces yielding of the disc-shaped panel caused by pressure drop across the disc-shaped panel. 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 panel while still allowing fluid to flow freely through the support frame. In this way, the disc-shaped panel can be relatively thin. From an acoustic perspective, thin and thick panels perform similarly. However, from a flow perspective, thin panels generate less frictional losses than thick panels. Moreover, thin panels are easier and less costly to manufacture.

[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 of building 3D objects by adding successive adjacent layers of material. The layers fuse together (e.g., naturally or via a subsequent fusing process) to form the 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 modeling (MJM). 3D printing is advantageous because it wastes less material than known machining operations. Thus, 3D printing disc-shaped plates results in a relatively low cost noise attenuator. Further, 3D printing is advantageous because it can be used to form high density features, such as thousands of smaller diameter openings (flow paths) in the plate, which can be infeasible for known machining processes. Smaller diameter openings produce noise at higher acoustic frequencies than larger diameter openings. The human hearing range is 20-20,000 Hertz (Hz). Thus, using smaller diameter openings tends to shift noise frequencies up to frequencies that are barely or not at all audible to the human ear.

[0052] In some examples, the size of the disc-shaped plate can exceed the printing capabilities of a 3D printer. In particular, the diameter of the disc-shaped plate can be larger than the footprint or build platform of the 3D printer. Thus, in some examples disclosed herein, the disc-shaped plate is formed from multiple portions, such as sector or corner portions. For example, the disc-shaped plate can be formed from multiple sector-shaped plates. Each of the sector-shaped plates can occupy one sector of a circle. For example, the disc-shaped plate can be formed from 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 that 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, multiple sector-shaped plates are printed simultaneously during the same print batch. 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 print batch. After the sector-shaped plates are built, the sector-shaped plates can be coupled to a support frame to form the disc-shaped plate. Using a support frame enables the disc-shaped plate to be formed from one or more portions. In other examples, the disc-shaped plate can be manufactured as a single piece or multiple portions in a conventional machining manner (e.g., perforating a metal plate, machining a plate, stacking metal plates, etc.).

[0053] Also disclosed herein are example disc-shaped panels formed from a plurality of sector-shaped panels without the use of support structures (e.g., support frames) or fasteners (e.g., threaded fasteners). The sector-shaped panels can be arranged together to form a disc-shaped panel that can be disposed in a passage of a fluid body, such as a noise attenuator body. The disc-shaped panel can be divided into any number of sector-shaped panels (e.g., two, three, four, five, etc.). Each of the sector-shaped panels 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-shaped panels are arranged together, the first mating feature of each of the sector-shaped panels engages or mates with the second mating feature of one of the adjacent sector-shaped panels. In this way, at least a portion of each of the sector-shaped panels overlaps with an adjacent one of the sector-shaped panels in an axial direction. These mating features serve to interlock the sector-shaped panels to reduce or prevent the sector-shaped panels from bending or axially displacing under the pressure of the fluid flow. These mating features can be designed to prevent axial displacement in an upstream direction, a downstream direction, or both. Various different shapes of mating features are disclosed herein.

[0054] Once the sector-shaped panels are combined into a disc-shaped panel, the disc-shaped panel can be installed in an attenuator body. In some examples, the peripheral region of the disc-shaped panel is clamped between two structures (e.g., an outlet flange of the attenuator body and an inlet flange of a downstream duct) such that the disc-shaped panel fills or covers the fluid passage. This clamping prevents radial and axial movement, and the interlocking mating features prevent bending and axial movement of the sector-shaped panels in the fluid passage. As a result, no support frames or fasteners are needed. This greatly reduces manufacturing costs and assembly and removal or disassembly times.

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

[0056] While many of the example plates and plate assemblies disclosed herein are described in connection with a noise attenuator, it should be appreciated that the example plates and plate assemblies can be used in other devices that utilize multipath flow plates. For example, a flame arrestor similarly uses one or more plates having small openings to allow fluid to flow in one direction, but prevent or reduce the flow of a flame in the opposite direction. Any of the examples disclosed herein can also be used as a flame arrestor plate.

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

[0058] In FIG. 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 a characteristic of a fluid 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.) that passes through a passageway 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 pipe 110. The regulating valve 102 receives the 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 pressure of the fluid at the regulating valve outlet 108 (e.g., to about 10 psi, several hundred psi, to a pressure just below the inlet pressure, etc.) based on a predetermined or preset setting. 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 can generate an unacceptable level of noise (e.g., greater than 85 decibels).

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

[0060] FIG. 2 This 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 connection at the inlet 204 to a regulating valve outlet 108 (e.g., via a threaded fastener). FIG. 1 The body 200 also has an inlet flange 208. The body 200 also has an outlet flange 210 at an outlet 206 that is coupled (e.g., via threaded fasteners) to an inlet flange 212 of a downstream conduit 112. The noise attenuator 100 includes one or more structures to reduce noise from 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 this disclosure. The plate assembly 214 is coupled to a 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 a 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 substantially the same as and / or fills a portion of the fluid channel 202. The disc-shaped plate 216 influences the flow of fluid through the body 200 to reduce audible noise.

[0062] The disc plate 216 includes an opening (e.g., orifice, perforation, etc.) defining a flow path through the disc plate 216 and thus through the fluid channel 202. The opening is located in... FIG. 3 The following is cited in more detail. Fluid flows from an upstream source (e.g., from the outlet of a control valve 108) through a disc 216 in fluid passage 202 into inlet 204 and through outlet 206 to downstream conduit 112. The disc 216 causes a pressure drop in the flowing fluid, which slows the fluid and reduces noise caused by the flowing fluid. Therefore, in operation, the noise attenuator 100 reduces noise generated by the flow through process control devices (e.g., FIG. 1 The fluid passage of the fluid control valve 102 and / or the fluid control valve assembly (e.g., FIG. 1a plot of audible noise caused by high energy fluid of the fluid passageway 202 of the noise attenuator 100 of the fluid regulating valve assembly 104.

[0063] In the illustrated example, the disc-shaped plate 216 is supported in the fluid passageway 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 illustrated example, 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 conduit 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 illustrated example, the support frame 218 is disposed downstream of the disc-shaped plate 216 in the fluid passageway 202. The support frame 218 prevents or reduces bending in the disc-shaped plate 216 that can be caused by pressure drops across the disc-shaped plate 216. In this way, the disc-shaped plate 216 can be relatively thin, which results in less frictional losses than a thicker plate.

[0064] In the illustrated example, a portion of the fluid passageway 202 is angled or tapered between the inlet 204 and the outlet 206. This diverging shape of the fluid passageway 202 enables the fluid to expand and reduce in velocity to dissipate energy of the fluid flow and / or to reduce noise. In other examples, the fluid passageway 202 can 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 such that the plate assembly 214 is disposed at another location within the fluid passageway 202 (e.g., closer to the inlet 204).

[0066] In the illustrated example, the noise attenuator 100 includes additional plates 228, 230 (sometimes referred to as inner plates) disposed in the fluid passageway 202 upstream of the plate assembly 214. The plate 228 is engaged with a ledge 231 in the plate assembly 214. The plate 228 can be mounted from the inlet 204 and the plate 230 can be mounted from the outlet 206. The plates 228, 230 are coupled via a plurality of rods 232 (one of which is visible in FIG. 2). In some examples, the rods 232 are threaded rods that are coupled to the plates 228, 230 via nuts. In other examples, the rods 232 are not threaded. FIG. 2The plates 228, 230 include openings that define flow paths through the respective plates 228, 230 to attenuate noise. The plates 228, 230 progressively slow down and reduce the noise of the flowing fluid. In this example, the rod 232 is not coupled to the plate assembly 214. Thus, in this example, the plate assembly 214 (e.g., end plate) is not coupled to the plates 228, 230 (e.g., inner plates). In other examples, the rod 232 can extend to and be coupled to the plate assembly 214. Additionally or alternatively, in some examples, one or more spacers can be disposed between and in contact with the second plate 230 and the disc plate 216. In such examples, the spacers transfer the load from the plates 228, 230 to the plate assembly 214. In other examples, the noise attenuator 100 can include more or fewer inner plates. In some examples, the noise attenuator 100 can not include any inner plates, such that the disc plate 216 is the only plate implemented in the noise attenuator 100.

[0067] FIG. 3 is a perspective view of an example plate assembly 214 including the disc plate 216 and the support frame 218. In the illustrated example, the support frame 218 has a body 300, which is a ring. The disc plate 216 can be coupled to the body 300 of the support frame 218. In this example, the disc 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 referenced in FIG. 3 ). Any number of threaded fasteners can be used. Thus, the disc plate 216 is removably coupled to the support frame 218. In other examples, the disc plate 216 can 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 to be coupled to the body 200 FIG. 2 ) of the noise attenuator 100 FIG. 2 ) to dispose the disc plate 216 in the fluid passage 202 FIG. 2 ). The flange 222 has openings 304 to receive threaded fasteners 306 (e.g., bolts, screws, etc.) (one of which is referenced in FIG. 3 ) for coupling the support frame 218 to the body 200.

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

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

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

[0072] Each of the sector-shaped plates 310-314 includes a plurality of openings 316 (one of which is referenced on each of the sector-shaped plates 310-314). The openings 316 form flow paths through the respective sector-shaped plates 310-314 to attenuate noise. When the plate assembly 214 is disposed in the fluid passage 202( FIG. 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 diameter). In some examples, all of the openings 316 have the same cross-sectional size or diameter. In some examples, certain ones 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 that align with the openings FIG. 4 are shown in more detail. In the illustrated example, 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 apart from one another.

[0073] FIG. 4 A plate assembly 214 is shown FIG. 3 . In this example, the second sector plate 312 and the third sector plate 314 have been removed, as have the threaded fasteners 302, 306. Only the first sector plate 310 is shown on the support frame 218. As shown FIG. 4 , the body 300 of the support frame 218 includes a plurality of openings 400 (one of which is referenced in FIG. 4 ). The openings 400 have a larger cross-sectional area than the openings 316 in the disc-shaped plate 216. The openings 400 are formed by one or more structural members that extend across the body 300. For example, as shown FIG. 4 , the support frame 218 has a plurality of radially extending ribs 402 (one of which is referenced in FIG. 4 ) and a plurality of rings 404 (one of which is referenced in FIG. 4 ). The arrangement of the ribs 402 and the rings 404 define the openings 400 through the body 300. The ribs 402 and the rings 404 provide a large area for the support of the disc-shaped plate 216 to prevent or reduce bending of the disc-shaped plate 216. In particular, the ribs 402 and the rings 404 create a larger contact area that distributes the load caused by the pressure on the disc-shaped 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 flow requirements and support requirements. Generally, the smaller the contact area between the disc-shaped plate 216 and the support frame 218, the greater the available flow area. However, more contact area between the disc-shaped plate 216 and the support frame 218 reduces the plate thickness requirements. In other examples, the support frame 218 can not include any rings. Instead, the support frame 218 can include only one or more ribs. While the disc-shaped plate 216 is in contact with the support frame 218 in this example, in other examples, one or more spacers can be disposed between the disc-shaped plate 216 and the support frame 218.

[0074] The support frame 218 is constructed from a rigid material. For example, the support frame 218 can be constructed from steel (e.g., carbon steel, stainless steel, etc.). In other examples, the support frame 218 can be constructed from 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 from 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 rings 404, is constructed as a single, unitary part or component. In other examples, the support frame 218 can be constructed from multiple parts that are coupled together (e.g., via fasteners, welding, etc.).

[0075] As described above, the openings 316 in the disc-shaped plate 216 can form a set that aligns with the openings 400 in the support frame 218. Thus, the openings 316 are not formed throughout the 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 provided 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 FIG. 3 may be used to couple the two sector-shaped plates 310-314 to the support frame 218. This reduces the number of threaded fasteners used to couple the sector-shaped plates 310-314 to the support frame 218. For example, as shown in FIG. 4 the first sector-shaped plate 310 has a first radial edge 406. The first radial edge 406 has three grooves 408 (one of which is referenced in FIG. 4 ). Each of the grooves 408 forms half of a fastener hole. The corresponding radial edge on the third sector-shaped plate 314 FIG. 3 has matching grooves that form the other half of the fastener hole. When the third sector-shaped plate 314 is disposed proximate to the first sector-shaped plate 310, the grooves form a fastener hole. The threaded fastener 308 FIG. 3 extends through the fastener hole and into a hole 410 (one of which is referenced in FIG. 4 ) formed in the support frame 218.

[0077] FIG. 5 A cross-sectional area of the support frame 218 is shown. The threaded fastener 308 (one of which is referenced in FIG. 5 ) couples the first sector-shaped plate 310 to the support frame 218. The threaded fastener 302 extends through a groove 408 (one of which is referenced in FIG. 5 ) in the first sector-shaped plate 310 and into a corresponding hole 410 (one of which is referenced in FIG. 5 ) in the support frame 218. In this example, the holes 410 in the support frame 218 are threaded, but the grooves 408 in the first sector-shaped plate 310 are not threaded. The second sector-shaped plate 312 and the third sector-shaped 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, second, and / or third sector-shaped plates 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 printing machine. Thus, each of the sector plates 310-314 is constructed via layers of a molten material, such as metal. Because 3D printing can be used to form plates with high density features, such as thousands of small flow paths, 3D printing is advantageous. Further, 3D printing is capable of forming small features such as the openings 316. As such, the size of the openings 316 can be smaller than openings formed using known machining techniques.

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

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

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

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

[0083] In some examples, the disc plate 216 is constructed via 3D printing, while the support frame 218 is constructed via traditional 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 in the 3D printer 600.

[0084] Because 3D printing involves building material layer by layer, 3D printing has limitations with overhanging surfaces. Most 3D printers have a critical angle, such as 45°. Any surface that would be tilted beyond that critical print angle can require temporary support. Otherwise, the material can yield or spread out when printing.

[0085] For example, because the sector plates 310-314 are printed vertically, the openings 316 can not be formed as circular. As shown in FIG. 3, the openings 316 can be formed as tear drops. 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 tear drop shaped. The upper portion of the opening 316 is printed at a maximum allowed angle, which can be 45°, for example. This results in the tear drop shaped opening. Other openings 316 can have similar shapes. The tear drop shaped opening does not adversely affect the flow of fluid through the opening 316.

[0086] In other examples, the openings 316 can have different shapes. For example, if the disc plate 216 is printed in a horizontal orientation, as shown in FIG. 4, the openings can be formed as circular or rounded. FIG. 7B In other examples, the openings 316 can have different shapes (e.g., hexagonal, polygonal). The flow paths created through the openings 316 can be axial straight, overlapping, rotational, or twisted. In some examples, all of the 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 plate 216 or within the same noise attenuator.

[0087] In other examples, the disc-shaped plate 216, formed as a single piece or from multiple sector-shaped plates, can be constructed through conventional (subtractive) manufacturing operations. For example, the disc-shaped plate 216 and / or the sector-shaped plates 310-314 can be a perforated metal plate, a machined plate, a stacked metal plate, etc. Thus, the disc-shaped plate 216 can be a perforated metal plate of a single piece, a stacked perforated metal plate (e.g., coupled via threaded fasteners), portions 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 partial machined part (single or partial). In some examples, the disc-shaped plate 216 and the support frame 218 comprise a single unitary part or component. For example, the entire plate assembly 214 can be printed as a single part. While only one disc-shaped plate is coupled to the support frame 218 in the example shown above, in other examples, multiple disc-shaped plates can be stacked and coupled to the support frame 218. The disc-shaped plates can be coupled via threaded fasteners. In some examples, such as in cases where high back pressure is experienced, a second support frame can be provided upstream of the disc-shaped plate 216. Thus, the disc-shaped plate 216 can be sandwiched between two support frames.

[0088] FIG. 8 is a perspective view of an example support frame 218. As described above, the support frame 218 can be constructed from a single unitary 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 disc-shaped plate 216 (and the fluid channels 202) while also allowing fluid to flow through the support frame 218. FIG. 2 ) in the fluid channels 202( FIG. 3 and FIG. 4 ). The support frame 218 can have other arrangements or layouts of structural members.

[0089] For example, FIG. 9 is an end view of another example support frame 900 that can be used in place of the support frame 218. The support frame 900 has an arrangement of structural members to support the disc-shaped plate 216. FIG. 10 is a perspective view of another example support frame 1000 that can be used in place of the support frame 218. The support frame 1000 has an arrangement of structural members to support the disc-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-shaped 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, support frame 900 can have better flow properties than support frame 1100 because support frame 900 has less structure at the center. However, support frame 1100 can be stronger than support frame 900 because support frame 1100 adds structure at the center and, thus, can be thinner in size than support frame 900. As another example, support frame 1000 can have better flow properties than support frame 218, but support frame 1000 can be weaker than support frame 218 because support frame 1000 does not have a center ring as in support frame 218.

[0090] FIG. 12 and FIG. 13 is a perspective view of an example shell 1200 (also referred to as a noise attenuator assembly) that can be used to attenuate noise of fluid flowing in a fluid body. For example, shell 1200 can be installed in fluid passage 202 FIG. 1 ) of noise attenuator 100 FIG. 2 ) as a supplement or replacement of other plates. Example shell 1200 includes a plurality of plate assemblies that form a plurality of noise attenuation stages.

[0091] In the example shown, shell 1200 includes a first plate assembly 1201 that includes a first disc-shaped plate 1202 for attenuating noise. First disc-shaped plate 1202 has a plurality of openings 1204 (one of which is referenced in FIG. 12 ) that form a flow path through first disc-shaped plate 1202. First disc-shaped plate 1202 is coupled to and / or otherwise supported by a first support frame 1206 that operates similarly to support frame 218 disclosed above. First support frame 1206 is disposed downstream of first disc-shaped plate 1202 when shell 1200 is disposed in a fluid body. First support frame 1206 has a plurality of radially extending ribs 1208. Any number of ribs can be employed. First support frame 1206 prevents or reduces bending of first disc-shaped plate 1202 caused by pressure differentials across first disc-shaped plate 1202. In this way, first disc-shaped plate 1202 can be relatively thin in size because first disc-shaped plate 1202 does not need structural rigidity to withstand pressure differentials as compared to known noise attenuator plates. Such thin plates are easier and less costly to manufacture.

[0092] In some examples, shell 1200 includes one or more additional plate assemblies for attenuating noise. For example, as FIG. 12 and 13As shown, the housing 1200 includes a second plate assembly 1209 including a second disc-shaped plate 1210 and a third plate assembly 1211 including 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 flow paths. The second disc-shaped plate 1210 is coupled to and / or otherwise supported by a second support frame 1214. The third disc-shaped plate 1212 is coupled to and / or otherwise supported by a second support frame 1216. In other examples, the housing 1200 can include more than three plate assemblies.

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

[0094] In the illustrated example, the first plate assembly 1201, the second plate assembly 1209, and the third plate assembly 1211 are coupled to and spaced apart along a center rod 1218. The center rod 1218 is coupled to and extends from a base 1220. To install the housing 1200 in a fluid body, the base 1220 can 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 can be coupled to the body 200 of 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 passage 202.

[0095] In this example, the first disc-shaped plate 1202, the second disc-shaped plate 1210, and the third disc-shaped plate 1212 are perforated plates. The first disc-shaped plate 1202, the second disc-shaped plate 1210, and the third disc-shaped plate 1212 can be constructed via a machining process. In other examples, the first disc-shaped plate 1202, the second disc-shaped plate 1210, and / or the third disc-shaped plate 1212 can be constructed via other manufacturing processes. In some examples, the first disc-shaped plate 1202, the second disc-shaped plate 1210, and / or the third disc-shaped plate 1212 are constructed via 3D printing (e.g., by FIG. 6of the 3D printer 600) configurations. In this example, each of the first, second, and third disk-shaped plates 1202, 1210, 1212 is a single unitary part or component. In other examples, any of the first, second, and / or third disk-shaped plates 1202, 1210, 1212 can 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 can be extruded into the shape of the support frames 1206, 1214, 1216. The cylinder can then be cut into multiple sections to form the individual support frames 1206, 1214, 1216. The support frames 1206, 1214, 1216 can be cut to size (length) according to the specific application load requirements. As 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 can be used in each of the plate assemblies 1201, 1209, 1211. In other examples, the support frames 1206, 1214, 1216 can 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 can be larger than their associated support frames 1206, 1214, 1216. For example, as shown in FIG. 12 and FIG. 13 As shown, the diameter of the first disk-shaped plate 1202 is larger than the diameter of the first support frame 1206. The disk-shaped plates 1202, 1210, 1212 are sized to substantially fill the fluid channel 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. As FIG. 15As shown, plate assemblies 1201, 1209, and 1211 are coupled to a central rod 1218. In some examples, more than one rod may be used to connect plate assemblies 1201, 1209, and 1211. In the example shown, plate assemblies 1201, 1209, and 1211 are spaced apart from each other by spacers 1500. Plate assemblies 1201, 1209, and 1211 may be spaced apart by any desired distance. In some examples, spacers 1500 are constructed via an extrusion process. In other examples, plate assemblies 1201, 1209, and 1211 may not be spaced apart. Alternatively, plate assemblies 1201, 1209, and 1211 may be stacked or arranged adjacent to each other (e.g., in contact).

[0099] The width of the structural members (e.g., rib 1208) and the axial length of the support frames 1206, 1214, and 1216 can be varied depending on the desired application. For example, a user expecting increased flow rate can use a support frame with thinner ribs but a longer axial length. In another example, a user expecting significant noise reduction can use a multi-stage noise attenuator, where each stage supports a smaller voltage drop compared to a noise attenuator with fewer stages.

[0100] FIG. 16 This is a flowchart illustrating an example method 1600 for manufacturing a disc plate and mounting the disc plate in the fluid body of a noise attenuator. Example method 1600 can be used to manufacture and mount any example disc plate disclosed herein having multiple plate portions or sectors.

[0101] In box 1602, example method 1600 involves printing multiple sector plates via a 3D printer. For example, as... FIG. 6 As shown, the first, second, and third sector plates 310-314 are printed via a 3D printer 600. Sector plates 310-314 include openings 316 forming flow paths. Each sector plate in 310-314 can be of the same size (e.g., each is a 120° sector) or of different sizes. In some examples, each sector plate in 310-314 is printed in a vertical orientation. This allows multiple sector plates to be printed side-by-side in the same printing batch. Therefore, sector plates 310-314 can be printed simultaneously as part of the same printing batch. In some examples, one or more post-processing operations (e.g., drilling, cutting, sanding, etc.) can be performed to smooth the surface of the sector plates 310-314.

[0102] In box 1604, example method 1600 includes coupling multiple sector plates to a support frame. For example, as... FIG. 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 two sector plates 310-314 to the support frame 218.

[0103] At block 1606, the example method 1606 includes coupling the support frame to the fluid body such that the disc-shaped plate formed by the plurality of sector plates is disposed in the fluid passage of the fluid body. For example, as shown in FIGS. 1-2, 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 passage 202. The support frame 218 can 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 can be printed as a single plate, which can then be coupled to the support frame 218 and disposed in the fluid passage 202. FIG. 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 passage 202. The support frame 218 can 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 can be printed as a single plate, which can then be coupled to the support frame 218 and disposed in the fluid passage 202.

[0104] If the plate is not composed of multiple plate sectors or portions, the plate can be manufactured as a monolithic plate via 3D printing or by other conventional manufacturing processes (e.g., laser cutting, water jet cutting, drilling, etc.) and similarly coupled to a support frame. For example, FIG. 12 The disc-shaped plates 1202, 1210, 1212 in FIGS. 12-13 are monolithic plates. The disc-shaped plates 1202, 1210, 1212 can be machined plates. The disc-shaped plates 1202, 1210, 1212 are coupled to respective support frames 1206, 1214, 1216, which they are coupled to (as a shell) and / or otherwise disposed in the fluid passage of the fluid body.

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

[0106] In the illustrated example, the disc-shaped plate 1700 is formed or defined by a plurality of sector plates. Specifically, in this example, the disc-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. Sector plates 1702-1708 form the disc-shaped plate 1700 when arranged together. In this example, each sector plate 1702-1708 forms a 90° sector of a circle when arranged together. In other examples, the disc-shaped plate 1700 may be formed by more or fewer sector plates. For example, the disc-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., forming 90° of the disc-shaped plate 1700. In other examples, one or more sector plates 1702-1708 may have different dimensions. For example, three sector plates may each form 100° of disk plate 1700, while a fourth sector plate may form 60° of disk plate 1700.

[0107] Each of the sector plates 1702-1708 has multiple extensions through the respective sector plate 1702-1708 opening 1710 (one of which is connected to...) FIG. 17 (Related to the first sector plate 1702). Opening 1710 forms a flow path through the corresponding sector plates 1702-1708 to attenuate noise. Disc plate 1700 has a first side 1712, a second side 1714 opposite to the first side 1712, and an outer peripheral edge 1716. When disc plate 1700 is installed in the fluid body, one of sides 1712 and 1714 faces upstream, and one of sides 1712 and 1714 faces downstream.

[0108] In some examples, sector plates 1702-1708 are constructed via 3D printing. For example, sector plates 1702-1708 can be made by... FIG. 6 The printer 600 prints the disks. Therefore, each of the sector plates 1702-1708 is constructed via layers of molten material (e.g., metal). In some examples, the diameter of the disk plate 1700 can be larger than the printing capacity of the 3D printer. Therefore, printing individual sector plates 1702-1708 allows the disk plate 1700 to be constructed via 3D printing. As mentioned above, 3D printing can form extremely small openings. Furthermore, 3D printing wastes minimal material compared to machining processes. In this example, each sector plate 1702-1708 is identical, i.e., it has the same shape and size. Therefore, four identical sector plates can be manufactured using the same printed model, which simplifies manufacturing and assembly.

[0109] FIG. 18The separate 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 mates 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 an outer 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 can also be referred to as locking features. The mating features 1804, 1806 can be male and female 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, third, and fourth sector plates 1704-1708 are the same as the first sector plate 1702. When the sector plates 1702-1708 are assembled into the disc-shaped plate 1700, the first mating feature 1804 of each of the sector plates 1702-1708 engages 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 two adjacent sector plates 1702-1708 in an 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 refers to perpendicular to the diameter or radius of the disc-shaped plate.

[0111] This mating design prevents the sector plates 1702-1708 from axially shifting or moving under high pressure of the fluid flow. For example, if a uniform force is applied across the first side 1712 (e.g., the upstream facing side) or the second side 1714 (e.g., the downstream facing side) 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 shifting. One force component is transmitted at the contact surface of the first mating feature 1804 and the second mating feature 1806 parallel to the first side 1712 and the second side 1714 of the disc plate 1700. This force is contained by the step or other parallel surface feature of the mounting disc plate 1700 (e.g., by the shoulder 1920 of the recess 1918 shown in FIG. 19 FIG. 19B). Another force component can be transmitted at the inclined surface that translates to a radially separating force (e.g., the inclined surface of the first mating feature and the second mating feature 1804, 1806). This force component is contained by the inner diameter of the cavity of the mounting disc plate 1700 (e.g., by the inner diameter surface 1921 of the recess 1918 shown in FIG. 19 FIG. 19B). Another force component can be transmitted at the inclined surface that translates to a radially separating force (e.g., the inclined surface of the first mating feature and the second mating feature 1804, 1806). This force component is contained by the inner diameter of the cavity of the mounting disc plate 1700 (e.g., by the inner diameter surface 1921 of the recess 1918 shown in

[0112] In some examples, if a uniform load is applied across the disc plate 1700, the mating design resists motion, but if an uneven force (e.g., a point force) is applied to a particular location on one of the sector plates 1702-1708, the disc plate 1700 can be vulnerable and can collapse. For example, referring to FIG. 17 FIG. 19B, if a point force is applied in the direction of the arrow near the edge of the third sector plate 1706, the point force can create a torque on the third sector plate 1706 that causes the third sector plate 1706 to twist because there is no overlapping mating feature behind the third sector plate 1706 near this edge. Other example mating feature designs are disclosed herein that have a double overlap design such that a point force does not cause twisting or collapse 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 and second mating features 1804 and 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 and second mating features 1804 and 1806 align with corresponding openings 1710 in the first and second mating features of 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 can not include openings along the portions of the sector plates 1702-1708 that form the first and / or second mating features 1804 and 1806.

[0114] FIG. 19 is a perspective cross-sectional view of an example noise attenuator 1900 in which the example disc plate 1700 can be implemented. The noise attenuator 1900 includes a body 1902 that defines a fluid passageway 1904 between an inlet 1906 and an outlet 1908. The body 1902 has an inlet flange 1910 at the inlet 1906 to couple (e.g., via threaded fasteners) to an upstream device or piping. For example, the inlet flange 1910 can couple to the outlet flange 110 of the regulator valve 100 and / or the outlet flange 114 of the outlet piping 116 shown in FIGS. 1-3. The body 1902 also has an outlet flange 1912 at the outlet 1908 to couple (e.g., via threaded fasteners) to an inlet flange 1914 of a downstream pipe 1916 as shown in FIG. 4. FIG. 1 and FIG. 2 In other examples, the noise attenuator 1900 can couple to and / or otherwise integrate with any other type of process control device (e.g., a valve) and / or any other device that changes a property of a fluid and produces noise. The body 1902 also has an outlet flange 1912 at the outlet 1908 to couple (e.g., via threaded fasteners) to an inlet flange 1914 of a downstream pipe 1916 as shown in FIG. 4. FIG. 19

[0115] ​In this example, the disc-shaped plate 1700 is disposed at or near the outlet 1908 in the fluid passage 1904. Thus, 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 such that the outer peripheral region of the first side 1712 of the disc-shaped plate is engaged with the shoulder 1920 and the outer peripheral edge 1716 is engaged with or proximate to the inner diameter surface 1921. The inlet 1924 of the downstream tube 1916 has a smaller diameter than 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 outer 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 can 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 illustrated example, the thickness or depth of the recess 1918 is the same as the disc-shaped plate 1700. This helps to prevent leaks that can occur between the sector-shaped plates 1702-1708 in the radial direction. Moreover, this design also eliminates the need for an end plate O-ring seal body 1902 and / or end plate bolting to the body 1902 compared to known attenuators.

[0117] Moreover, as disclosed above, the sector-shaped plates 1702-1708( FIG. 17The mating features prevent sector plates 1702-1708 from axially displacing and / or folding under the pressure of fluid flow through disc plate 1700. The mating features can be designed to prevent axial separation in the upstream, downstream, or both directions. Therefore, the example disc plate 1700 does not require threaded fasteners or support structures (e.g., a central shaft, support frame, etc.). In this example, disc plate 1700 is supported solely by the clamping of its outer peripheral region. Eliminating the need for fasteners eliminates many of the disadvantages experienced by fasteners. For example, fasteners can loosen over time and may require retightening. Fasteners typically also require support structures. Furthermore, fasteners create a limited mating surface that bears high stress. On the other hand, the example mating feature design provides a larger, lower-stress mating surface. Moreover, assembly is easier without fasteners because disc plate 1700 can be easily inserted into recess 1918 before coupling the outlet flange 1912 of body 1902 to the inlet flange 1914 of downstream pipe 1916. This reduces the cost associated with assembling the noise attenuator 1900. Furthermore, because the disc plate 1700 is sized to fit a specific recess, it can be manufactured to the required structural thickness, thus eliminating the need for adjacent support structures.

[0118] In other examples, sector panels 1702-1708 may be coupled or supported by fasteners or support structures, for example, in the case of remote assembly or temporary shelving storage (external to body 1902). In some examples, panel-to-panel interfaces may be reinforced with adhesive, coupling elements, fasteners, or external retaining rings.

[0119] In the illustrated example, the noise attenuator 1900 includes additional plates 1930, 1932 (sometimes referred to as inner plates) disposed in a fluid channel 1904 upstream of the disc plate 1700. In the illustrated example, plates 1930, 1932 are connected via a plurality of rods 1934 (one of which is in…) to prevent or reduce bending of plates 1930, 1932. FIG. 19 (Referenced in the middle) are coupled. Plates 1930, 1932 include openings defining flow paths 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 plate 1700. Therefore, in this example, disc 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 plate 1700. Additionally or alternatively, in some examples, one or more spacers may be provided between each of the plates 1930, 1932 and / or between plate 1932 and disc plate 1700. For example, FIG. 19An example spacer 1936 is shown disposed between the plate 1932 and the disc plate 1700. Thus, upstream pressure loads from the plates 1930, 1932 are transmitted to the disc plate 1700 via the spacer 1936. In other examples, more spacers can be used. In other examples, no spacer can be disposed between the plate 1938 and the disc plate 1700. In other examples, more or fewer plates can be implemented. In this example, each of the plates 1930-1938 is a single piece of perforated metal. However, in other examples, one or more of the plates 1930-1938 can be the same as the disc plate 1700. Thus, multiple disc plates 1700 can be implemented. Separation distances between the plates can be achieved by axial spacers, hole steps, nuts, etc. In other examples, the noise attenuator 1900 can not include any inner plates, such that the disc plate 1700 can be the only plate implemented in the noise attenuator 1900.

[0120] FIG. 20 and FIG. 21 is a perspective view of the first sector plate 1702. The first sector plate 1702 has a first radial edge 1800 that forms a first mating feature 1804 and a second radial edge 1802 that forms a second mating feature 1806. As described above, in some examples, the first sector plate 1702 is fabricated by a 3D printing mechanism, such as the 3D printer 600 of FIG. 6 In some examples, the first sector plate 1702 is printed in a vertical orientation, starting at the second radial edge 1802, as indicated by the arrow direction in FIG. 20 This enables multiple sector plates to be printed side-by-side during the same print batch, similar to the arrangement shown in FIG. 6 In some examples, this results in the openings 1710 being teardrop shaped, similar to the openings 316 shown in FIG. 7A In other examples, the shape of the openings 1710 can be different. In other examples, the first sector plate 1702 can be printed in a different orientation (e.g., horizontal).

[0121] In some examples, the flow path formed by the openings 1710 is not uniformly shaped, but rather has a variable area and cross-sectional profile between the upstream face (e.g., the first side 1712 FIG. 17 ) and the downstream face (e.g., the second side 1714 FIG. 17 ) of the disc plate 1700. For example, in acoustic applications, one or more of the openings 1710 can have two or more stages of expansion, which improves noise reduction. In another example, in which only one stage of expansion is implemented, a 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. 22is a perspective view of another example sector plate 2200, which can be used to form a disc-shaped plate for a noise attenuator, similar to the sector plates 1702-1708 disclosed above. Multiple sector plates 2200 can be constructed and arranged together to form a disc-shaped plate. In particular, in this example, four sector plates 2200 can be arranged together to form one disc-shaped plate, as shown by way of example in FIG. 27 The resulting disc-shaped plate can be disposed in a fluid passageway with FIG. 19 the disc-shaped plate 1700 shown in FIG. 17B. The sector plates 2200 can be printed via a 3D printer, such as the printer 600 shown in FIG. 6

[0123] In the example shown, the sector plate 2200 has a first radial edge 2202 that forms a first mating feature 2204 and a second radial edge 2206 that forms a second mating feature 2208 that is 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 disc-shaped plate, the first mating feature 2204 of each of the sector plates 2200 engages or mates with the second mating feature 2208 of an adjacent one of the sector plates 2200. Thus, each of the sector plates 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 high pressure from fluid flow.

[0124] In the example shown, the sector plate 2200 has a first wall 2210 that forms a first side of the sector plate 2200 and a second wall 2212 that forms a second side of the sector plate 2200. The sector plate 220 has a first plurality of openings 2214 (one of which is referenced in FIG. 18A) extending between the first wall 2210 and the second wall 2212. The openings 2214 form flow paths through the sector plate 2200 to attenuate noise. FIG. 22

[0125] In some examples, the sector plate 2200 is substantially solid and the openings 2214 extend through the body of the sector plate 2200. For example, FIG. 23 An example of the sector plate 2200 taken along a center plane of the sector plate 2200 is shown in FIG. 18B. In this example, the interior body of the sector plate 2200 is substantially solid and the openings 2214 (one of which is referenced in FIG. 18B) extend through the solid body. FIG. 23

[0126] In other examples, the interior body of the sector plate 2200 can be partially hollow or include other structures, such as a lattice structure. For example, FIG. 24 ​​​Another cross-sectional version of the sector plate 2200 is shown. In this example, the sector plate 2200 has an internal lattice structure 2400. The internal lattice structure 2402 forms a plurality of openings 2402 (one of which is in... FIG. 24 (See reference in the original text). In this example, opening 2402 is rhomboid. In some examples, this rhomboid lattice structure allows for easier printing in the vertical direction by limiting wall overhangs. In other examples, the inner 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 The internal lattice structure 2400 and opening 2402 are shown. Opening 2402 is fluidly connected to the opening in the first wall 2210 and the second wall 2212. FIG. 22 The openings in the internal lattice structure 2400 are larger than the openings in the first wall 2210 and the second wall 2212. Therefore, each opening in the opening 2402 of the internal lattice structure 2400 is fluidly connected to a plurality of openings in the first wall 2210 and a plurality of openings in the second wall 2212.

[0127] FIG. 26 This is a side cross-sectional view of the sector plate 2200, showing an opening 2402 in the internal lattice structure 2400. The first wall 2210 has a first plurality of openings 2600 (three of which are in...). FIG. 26 (referring to the middle) and the second wall 2212 has a second plurality of openings 2602 (three of which are in FIG. 26 (See reference in the original text). The openings 2402 of the internal lattice structure 2400 fluidly connect a first plurality of openings 2600 and a second plurality of openings 2602. In some examples, the internal lattice structure 2400 is formed throughout the entire sector plate 2200, including portions forming first mating features 2204 and second mating features 2208. In other examples, the internal lattice structure 2400 is formed only in the center or main portion of the sector plate 2200, and the portions forming the first mating features 2204 and second mating features 2208 do 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. This results in lower manufacturing costs for the sector plate 2200 and a lighter disk plate. As mentioned above, the sector plate 2200 can be constructed using a 3D printer. The internal lattice structure 2400 can be formed during the 3D printing process. This internal lattice structure may not be achievable via conventional (subtractive) machining processes.

[0129] Furthermore, through this design, the first wall 2210 and the second wall 2212 effectively form two attenuator plates. 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. Therefore, this design results in two flow stages (dual expansion), which further improves the noise attenuation performance of the sector plate 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 disk plate may include a hollow cross-section or lattice structure, while one or more other portions may be solid. In another example, the entire sector plate may be a lattice structure without sidewalls. In such examples, the flow path has a constant cross-section over the plate thickness, defined by the lattice geometry. It should be understood that any example disk plate and / or individual sector plate disclosed herein may include the internal lattice structure disclosed in conjunction with that example or variations thereof.

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

[0132] When sector plates 2200, 2704-2708 are assembled into disc plate 2700, the first mating feature 2204 of each sector plate in sector plates 2200, 2704-2708 ( FIG. 2 The second mating feature 2208 of the adjacent sector plates 2200, 2704-2708 FIG. 2 The sector plates 2200, 2704-2708 are joined or fitted together. Thus, each sector plate 2200, 2704-2708 overlaps axially with two adjacent sector plates 2200, 2704-2708. This fit design prevents the sector plates 2702-2708 from axial displacement or movement under high pressure from fluid flow in the upstream or downstream direction. Due to the V-shaped overlap, in this example, isolated point forces will not cause one of the sector plates 2200, 2704-2708 to rotate or twist. Fitting features 2204, 2208 ( FIG. 22The internal locking design of the (e.g., 2200, 2704-2708) prevents twisting in both directions (radially outward torque and radially inward torque), thereby preventing folding between the sector plates 2200, 2704-2708.

[0133] FIG. 28A 、 FIG. 28B 、 FIG. 28C and FIG. 28D shows an example sequence of assembling the sector plates 2200, 2704-2708 into the disc plate 2700 FIG. 28D ). 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 of the sector plates 2200, 2704-2708 fit.

[0134] In some examples, each of the sector plates 2200, 2704-2708 can include an internal lattice structure, as disclosed in connection with FIG. 24-FIG. 26 . In other examples, the sector plates 2200, 2704-2708 can not include an internal lattice structure. Instead, as disclosed in connection with FIG. 23 , the openings can extend straight through the respective sector plates 2200, 2704-2708. For example, FIG. 29 shows a cross-sectional view of an example disc plate 2700, in which the disc plate 2700 does not include an internal lattice structure. Instead, the openings 2214 extend through the solid interior structure of the disc plate 2700.

[0135] In some examples, the openings 2214 are omitted from one or more portions of the sector plates 2202, 2704-2708 near the interface of the first mating feature 2204 and the second mating feature 2208 FIG. 22 . In some examples, this interface is relatively thin. For example, as shown in FIG. 29 , a first portion 2900 along the second radial edge 2206 of the first sector plate 2200 does not include an opening. Further, a second portion 2902 does not include an opening. The second portion 3202 corresponds to the radial edge forming the first mating feature of the second sector plate 2704. In other examples, one or more of these portions can still have an opening.

[0136] For example, FIG. 30 is another perspective view of an example disc plate 3000. The disc plate 3000 is substantially the same as the disc plate 2700 disclosed above. However, in this example, the disc plate 3000 does not include the portion 2902 in which the openings are omitted. FIG. 31 shows the disc plate 3000 with the first wall removed.

[0137] FIG. 32-FIG. 43Example disk-shaped plates are shown with various shape mating features. The mating features function substantially the same as the examples described above to prevent or reduce axial displacement of the sector-shaped plates. In some examples, the mating features overlap not only in the axial direction, but also in the circumferential direction. Thus, engagement can occur in a particular direction.

[0138] The openings through the various disk-shaped plates are not shown in FIG. 32-FIG. 43 However, it is understood that, FIG. 32-FIG. 43 The disk-shaped plates of can include a plurality of openings extending through the respective disk-shaped plates. FIG. 32-FIG. 43 Any of the disk-shaped plates of can include an internal lattice structure, similar to the internal lattice structures in the examples disclosed above. Each of the disk-shaped plates is formed by a plurality of sector-shaped plates. Any number of sector-shaped plates can be used. The sector-shaped plates can be printed in a 3D printer, such as FIG. 6 The 3D printer 600. Some FIG. 32-FIG. 43 The disk-shaped plates of are more suitable for machining operations due to the printing complexity. FIG. 32-FIG. 43 Any of the disk-shaped plates of can be disposed in a fluid passage with FIG. 19 The disk-shaped plates 1700 shown in

[0139] In some examples, such as in FIG. 42 and FIG. 43 The sector-shaped plates overlap in the axial direction with two other sector-shaped plates at the mating features. In other examples, the sector-shaped plates can be designed such that the sector-shaped plates overlap in the axial direction with more than two other sector-shaped plates at the mating features. In some examples, such as in FIG. 37 and FIG. 43 The disk-shaped plates can have a recess or opening in the center. This recess or opening can be used to receive a support member, such as a center rod. In some examples, the disk-shaped plates can include additional openings to receive other support rods for supporting the disk-shaped plates. If support rods or spacers are used, the disk-shaped plates can have regions that are completely solid or regions with thicker walls.

[0140] FIG. 44 is a flowchart representing an example method 4400 of manufacturing disk-shaped plates and installing the disk-shaped plates in a fluid body. The example method 4400 is described in conjunction with the disk-shaped plates 1700. FIG. 17 However, it is understood that the example method 4400 can 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-shaped plates via a 3D printer. For example, the sector-shaped plates 1702-1708 can be printed via a 3D printer, such as FIG. 6The 3D printer 600. In some examples, each of the sector plates 1702-1708 is printed in a vertical direction. This allows multiple sector plates to be printed side-by-side in the same print batch. The sector plates 1702-1708 can be printed simultaneously as part of the same print batch or at different times. In some examples, one or more post-processing operations (e.g., drilling, cutting, sanding, etc.) can be performed to smooth the surface of the sector plates 1702-1708. Each sector plate 1702-1708 includes a first mating feature 1804 and a second mating feature 1806 complementary to the first mating feature 1804. The sector plates 1702-1708 include an opening 1710. In some examples, the sector plates 1702-1708 may include an internal lattice structure.

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

[0143] In block 4406, example method 4400 includes coupling a disc plate to a fluid body such that the disc plate is disposed in a fluid channel of the fluid body. For example, as FIG. 19 As shown, a disc plate 1700 is disposed in the fluid passage 1904 of the body 1902 of the noise attenuator 1900. In some examples, the disc plate 1700 is coupled to the body 1902 by clamping its outer peripheral region between the body 1902 and the downstream pipe 1916. This clamping locks the outer peripheral region of the disc plate 1700 in place. Furthermore, the design prevents or reduces axial displacement of the sector plates 1702-1708. Thus, in some examples, method 4400 does not involve using threaded fasteners or support structures to construct the disc plate 1700 or to couple the disc 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 plate is coupled to or otherwise integrated with the body of the noise attenuator, any example plate and / or plate assembly disclosed herein may alternatively be directly coupled to or integrated into the body of a process control device that generates audible noise. For example, the disc plate may be coupled to the outlet of a control valve or valve to reduce noise as fluid leaves the control valve or valve.

[0145] Any of the example plates and / or plate assemblies disclosed herein can also be implemented in other devices that use multi-path flow plates, such as flame arrestors. In flame arrestor applications, the size of the flow paths can be determined based on the process gas using a specific maximum experimental safe gap (MESG) or orifice diameter. In some examples, the same plate can be stacked according to operating parameters. In some examples, plates with the same cross-section can 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 fluid flow through the plates. For example, many valves and other flow control devices have a top with an opening that is sealed with a cover plate. For example, if the valve needs to be serviced, 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 a cover that covers the cover plate. Instead, an example disc-shaped plate formed by a plurality of scallop plates with mating features can be used. In such examples, the scallop plates would not have flow path openings, but can be completely solid. For example, the inner diameter of the opening in the valve body can have a recess similar to the recess 1918 shown in the outlet 1908 of the center body 1902, and a plurality of scallop plates can be arranged into a disc-shaped plate and inserted into the recess. Then, a retaining ring or cross plate can be used to clamp or secure the outer peripheral region of the disc-shaped plate to the valve body. In this way, the disc-shaped plate can be used as a cover to cover or seal the opening. Such a disc-shaped plate with a plurality of scallop plates can be easier to install and remove than a traditional cover plate. Furthermore, this would enable larger plates to be built via 3D printing, which is advantageous because it can be used to create complex features in the scallop plates. FIG. 19

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

[0148] ​“Comprise” and “contain” (and all forms of these terms) are used herein as open-ended terms. Thus, whenever a claim employs any form of “comprise” or “contain” (e.g., comprises, comprise, comprising, comprises, contains, contained, containing, etc.) as a preamble, it is to be understood that additional elements, terms, etc. can be present in the corresponding claim or statement without exceeding the scope of the corresponding claim or statement. As used herein, when the phrase “at least” is used as a transitional term in, for example, the preamble of a claim, it is open-ended in the same manner as the transitional terms “comprise” and “include.” The term “and / or” when used in the form, for example, A, B, and / or C, means that any combination or subset of A, B, C is meant, for example, (1) A alone, (2) B alone, (3) C alone, (4) A with B, (5) A with C, (6) B with C, and (7) A with B and with C. As used herein in the context of describing structures, the phrase “at least one of A and B” is intended to refer to implementations including (1) at least one A, (2) at least one B, and (3) at least one of 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 implementations including (1) at least one A, (2) at least one B, and (3) any of at least one A and at least one B. As used herein in the context of describing performance or execution of processes, instructions, actions, activities, and / or steps, the phrase “at least one of A and B” is intended to refer to implementations including (1) at least one A, (2) at least one B, and (3) any of at least one A and at least one B. Similarly, as used herein in the context of describing performance or execution of processes, instructions, actions, activities, and / or steps, the phrase “at least one of A or B” is intended to refer to implementations including (1) at least one A, (2) at least one B, and (3) any of 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 multiple. 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. Furthermore, although individually listed, a plurality of means, elements or method actions can be implemented by, e.g., a single unit or processor. Additionally, although individual features can be included in different examples or claims, these can possibly be combined, and the inclusion of such features in different examples or claims does not imply that a combination of features is not feasible and / or advantageous.

[0150] From the foregoing, it will be appreciated that example multi-flowpath panels have been disclosed that can be advantageously employed in devices such as noise attenuators and flame arrestors. Some examples disclosed herein utilize a support frame to support the panel, which enables the use of relatively thin panels. Thin panels have reduced frictional losses relative to thicker panels. Thin panels are also easier to manufacture and less costly. Also disclosed are example panels formed from a plurality of matching or interlocking sector-shaped panels, and thus do not require fasteners or support structures. The example panels disclosed herein can be constructed via 3D printing, which is generally more efficient and results in less material waste than known machining processes. Furthermore, 3D printing also enables the formation of complex mating features, relatively small openings, and lattice structures that would generally be infeasible in traditional machining processes.

[0151] Example methods, devices, systems, and articles of manufacture 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 panel assembly for a noise attenuator. The panel assembly includes a support frame to be coupled to a main body of the noise attenuator. The support frame has a plurality of radially extending ribs. The panel assembly also includes a disc-shaped panel having a plurality of openings that form flow paths to attenuate noise. The disc-shaped panel is coupled to the support frame such that a load induced by pressure on the disc-shaped panel is distributed to the plurality of radially extending ribs of the support frame.

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

[0154] Example 3 includes the panel assembly of example 2, wherein each of the plurality of sector-shaped panels has the same shape and size.

[0155] Example 4 includes the panel assembly of example 2 or 3, wherein each of the plurality of sector-shaped panels is constructed via a layer of fused material.

[0156] Example 5 includes the panel 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-shaped 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-shaped 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 the 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 is arranged in groups that are aligned with the second plurality of openings.

[0162] Example 11 is a noise attenuator comprising a body defining a fluid passageway 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 passageway. The disc-shaped plate has a plurality of openings forming a flow path. The plate assembly further includes a support frame disposed downstream of the disc-shaped plate such that pressure-induced loads on the disc-shaped plate are 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 a downstream pipe.

[0165] Example 14 includes the noise attenuator of any of Examples 11-13, wherein the disc-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-shaped plates are coupled to the support frame.

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

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

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

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

[0171] Example 20 includes the method of Example 19, further comprising coupling the 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 panel for a noise attenuator. The disc-shaped panel includes a plurality of sector-shaped panels. The plurality of sector-shaped panels have openings that define flow paths. Each of the plurality of sector-shaped panels 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, such that when the plurality of sector-shaped panels are arranged together, the first mating feature of each of the plurality of sector-shaped panels mates with the second mating feature of an adjacent one of the plurality of sector-shaped panels.

[0173] Example 22 includes the disc-shaped panel of Example 21, wherein each of the plurality of sector-shaped panels has the same shape and size.

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

[0175] Example 24 includes the disc-shaped panel of any of Examples 21-23, wherein each of the plurality of sector-shaped panels is constructed via a layer of fused material.

[0176] Example 25 includes the disc-shaped panel of any of Examples 21-24, wherein the openings are teardrop-shaped.

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

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

[0179] Example 28 includes the disc-shaped panel of Example 27, wherein one of the third plurality of openings is fluidly connected to a first set of the first plurality of openings in the first wall and a second set of the second plurality of openings in the second wall.

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

[0181] Example 30 includes the disc-shaped panel of Examples 21-29, wherein the plurality of sector-shaped panels are not coupled by fasteners.

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

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

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

[0185] Example 34 includes the noise attenuator of any of Examples 31-33, wherein the plurality of sector-shaped 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 passageway upstream of the disc-shaped plate.

[0187] Example 36 is a method comprising printing a plurality of sector-shaped plates via a three-dimensional (3D) printer. The plurality of sector-shaped plates have openings defining flow paths. Each of the plurality of sector-shaped 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-shaped plates are printed by the 3D printer during a same print batch.

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

[0190] Example 39 includes the method of Example 38, further comprising coupling the disc-shaped plate to a fluid body such that the disc-shaped plate is disposed in a fluid passageway 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 fluid body and a downstream pipe.

[0192] Although specific example methods, apparatus and articles of manufacture have been disclosed herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatus and articles of manufacture falling within the scope of the claims.

[0193] The following claims are hereby incorporated by reference into this detailed description, each claim as it stands alone being a separate embodiment of the present disclosure.

Claims

1. A disc-shaped panel for a noise attenuator, the disc-shaped panel comprising: a plurality of sector-shaped panels having openings defining flow paths, each of the plurality of sector-shaped panels having 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, such that when the plurality of sector-shaped panels are arranged together, the first mating feature of each of the plurality of sector-shaped panels mates with the second mating feature of an adjacent one of the plurality of sector-shaped panels, and when the plurality of sector-shaped panels are arranged together, the first radial edge of each of the plurality of sector-shaped panels overlaps in an axial direction with an adjacent one of the plurality of sector-shaped panels, and the second radial edge of each of the plurality of sector-shaped panels overlaps in an axial direction with an adjacent one of the plurality of sector-shaped panels.

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

3. The disc-shaped panel of claim 1 or 2, wherein each of the plurality of sector-shaped panels is constructed via a layer of fused material.

4. The disc-shaped panel of claim 1 or 2, wherein the openings are teardrop-shaped.

5. The disc-shaped panel of claim 1 or 2, wherein the plurality of sector-shaped panels includes a first sector-shaped panel, the first sector-shaped panel comprising: a first wall forming a first side of the first sector-shaped panel, the first wall having a first plurality of openings; a second wall forming a second side of the first sector-shaped panel, the second wall having a second plurality of openings; and an internal lattice structure between the first wall and the second wall.

6. The disc-shaped panel of claim 5, wherein the internal lattice structure forms a third plurality of openings.

7. The disc-shaped panel of claim 6, wherein one of the third plurality of openings is fluidly connected with a first set of the first plurality of openings in the first wall and a second set of the second plurality of openings in the second wall.

8. The disc-shaped panel of claim 6 or 7, wherein the third plurality of openings are diamond-shaped.

9. The disc-shaped plate of claim 1 or 2, wherein, the plurality of sector-shaped panels are not coupled by fasteners.

10. A noise attenuator comprising: a body defining a fluid passageway between an inlet and an outlet; and a disc-shaped panel disposed in the fluid passageway, the disc-shaped panel having a plurality of openings forming flow paths for reducing noise of a fluid flowing in the fluid passageway, the disc-shaped panel formed by a plurality of sector-shaped panels having mating features such that when the plurality of sector-shaped panels are arranged together, a portion of each radial edge of each of the plurality of sector-shaped panels overlaps in an axial direction with an adjacent one of the plurality of sector-shaped panels.

11. The noise attenuator of claim 10, wherein the disc-shaped panel is disposed in the fluid passageway at or near the outlet.

12. The noise attenuator of claim 11, wherein an outer peripheral region of the disc-shaped plate is configured to be clamped between an outlet flange of the body and an inlet flange of a downstream pipe.

13. The noise attenuator of any one of claims 10-12, wherein the plurality of sector-shaped plates are not coupled by fasteners.

14. The noise attenuator of any one of claims 10-12, further comprising an additional plate disposed in the fluid passage upstream of the disc-shaped plate.

15. A method for manufacturing a disc-shaped plate for a noise attenuator, comprising: printing, via a three-dimensional (3D) printer, a plurality of sector-shaped plates having openings defining a flow path, each sector-shaped plate of the plurality of sector-shaped plates having 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, and, when the plurality of sector-shaped plates are arranged together, the first radial edge of each sector-shaped plate of the plurality of sector-shaped plates overlaps an adjacent one of the plurality of sector-shaped plates in an axial direction, the second radial edge of each sector-shaped plate of the plurality of sector-shaped plates overlaps an adjacent one of the plurality of sector-shaped plates in the axial direction.

16. The method of claim 15, wherein the plurality of sector-shaped plates are printed by the 3D printer during a same print batch.

17. The method of claim 15 or 16, further comprising assembling the plurality of sector-shaped plates to form a disc-shaped plate.

18. The method of claim 17, further comprising coupling the disc-shaped plate to a fluid body such that the disc-shaped plate is disposed in a fluid passage of the fluid body.

19. The method of claim 18, wherein an outer peripheral region of the disc-shaped plate is clamped between the fluid body and a downstream pipe.

Images