Framed Disc Plate Assemblies for Low-Loss Noise Attenuators
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Solution Overview
Problem
Existing noise attenuators in process control systems face challenges with thick, heavy plates that are difficult and costly to manufacture, prone to bending, and limited in feature density, leading to high frictional losses and increased assembly and transportation complexity.
Innovation Solution
The use of thin disc-shaped plates supported by a frame, manufactured via 3D printing, which distributes pressure-induced loads and allows for high-density, small openings, reducing noise and frictional losses while being easier and cheaper to produce.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thick plates are used in noise attenuators, then structural strength is improved, but weight and manufacturing cost increase
Solution Approach 1:
The plate is divided into a grid pattern with multiple cells, where each cell acts as an independent structural unit. This segmentation provides sufficient structural strength through the distributed grid framework while using thinner material overall, reducing the weight compared to a solid thick plate.
Solution Approach 2:
The plate employs a porous grid structure with controlled openings that maintains structural integrity while reducing material usage. The grid pattern creates a lightweight yet strong configuration that resists deformation under pressure differential.
2Strength
If thick plates are used in noise attenuators, then structural strength is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The plate design uses a modular grid pattern that can be manufactured using standard fabrication processes. The segmented structure allows for easier manufacturing compared to creating a solid thick plate with integrated flow channels, as the grid can be produced through conventional cutting, drilling, or additive manufacturing techniques.
Solution Approach 2:
The porous grid structure simplifies manufacturing by eliminating the need to machine complex internal channels through thick material. The open cell structure can be directly formed through various manufacturing processes, reducing production complexity and cost.
3Object-affected harmful factors
If thin plates with small openings are used, then noise attenuation is improved, but frictional losses increase
Solution Approach 1:
The plate is segmented into multiple cells with distributed openings, which creates numerous small flow paths. This segmentation allows for effective noise attenuation through the combined effect of multiple openings while distributing the flow resistance across many pathways, reducing overall frictional losses compared to a single large opening or dense pattern.
Solution Approach 2:
The design optimizes the parameters of the grid structure, including cell size, opening diameter, and opening distribution, to achieve the right balance between noise attenuation and flow efficiency. By carefully selecting these parameters, the plate maximizes noise reduction while minimizing pressure drop and frictional losses.
4Ease of manufacture
If thin plates are used, then manufacturing cost is reduced, but structural integrity under pressure drops
Solution Approach 1:
The thin plate is reinforced through segmentation into a grid pattern, where the interconnected cells provide structural support. This grid framework distributes mechanical loads across the plate surface, maintaining structural integrity under pressure differential despite the reduced plate thickness.
Solution Approach 2:
The porous grid structure in the thin plate provides both flow functionality and structural reinforcement. The distributed cells and struts create a lightweight yet strong configuration that maintains plate stability under operating pressures while allowing fluid passage.
Data Source
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AI summary
Plates and plate assemblies for noise attenuators and other devices and methods of making the same are described herein. An example plate assembly includes a support frame to be coupled to a body of the noise attenuator. The support frame has a plurality of radially extending ribs. The plate assembly also includes a disc-shaped plate having a plurality of openings forming flow paths to attenuate noise. The disc-shaped plate is coupled to the support frame such that pressure-induced loads on the disc-shaped plate are distributed to the plurality of radially extending ribs of the support frame.