Rib-Supported Sector Plate Assembly for Noise Attenuators

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing noise attenuators in process control systems face challenges with thick plates that are costly, difficult to manufacture, and prone to bending due to pressure-induced loads, leading to inefficiencies in noise reduction and increased frictional losses.

Innovation Solution

A plate assembly comprising a thin disc-shaped plate supported by a radially extending ribbed support frame, where the disc-shaped plate is formed by sector-shaped plates with mating features that interlock to prevent axial displacement, allowing for reduced thickness and lower manufacturing costs, and utilizing 3D printing for high feature density and minimal material waste.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If thick plates are used in noise attenuators, then structural strength against pressure-induced loads is improved, but manufacturing cost increases and manufacturing difficulty increases

Engineering Contradiction:

Improvestructural strengthVSAvoidmanufacturing difficulty

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The plate is divided into multiple sectors that are assembled together to form a complete circular plate. This segmentation allows thin individual sectors to be manufactured easily and then combined to create a structurally sound complete plate that resists pressure-induced loads through its distributed geometry and support frame configuration.

Inventive Principle:

Principle #1Segmentation

2Strength

If thick plates are used in noise attenuators, then structural strength against pressure-induced loads is improved, but manufacturing cost increases

Engineering Contradiction:

Improvestructural strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The plate thickness parameter is reduced from thick to thin, while compensating for structural strength through the segmentation into multiple sectors and the addition of a support frame with radially extending ribs, achieving the same structural performance at lower cost and reduced material usage.

Inventive Principle:

Principle #35Parameter changes

3Strength

If thick plates are used in noise attenuators, then structural integrity against pressure-induced loads is maintained, but frictional losses increase

Engineering Contradiction:

Improvestructural integrityVSAvoidfrictional losses

Core Design Contradiction:

StrengthVSLoss of energy

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Inventive Principle:

Principle #35Parameter changes

4Ease of manufacture

If thin disc-shaped plates are used in noise attenuators, then manufacturing cost decreases and frictional losses are reduced, but structural integrity against pressure-induced loads deteriorates

Engineering Contradiction:

Improvemanufacturing costVSAvoidstructural integrity

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A support frame with radially extending ribs is introduced as an intermediary structural element between the thin plate sectors and the pressure-induced loads. This support frame distributes and bears the mechanical stresses, allowing the plate itself to remain thin while maintaining overall structural integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

5Ease of operation

If sector-shaped plates with mating features are used, then ease of assembly is improved and axial displacement is prevented, but device complexity increases

Engineering Contradiction:

Improveease of assemblyVSAvoiddevice complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Mating features are incorporated on the radial edges of adjacent sectors that automatically interlock during assembly, causing the sectors to self-align and prevent axial displacement without requiring additional fasteners or complex assembly procedures. The structure serves its own alignment and securing function.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS11562726B2Plates and plate assemblies for noise attenuators and other devices and methods making the same

Publication Date: 2023.01.24 EMERSON PROCESS MANAGEMENT REGULATOR TECHNOLOGIES INC

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.