Segmented Noise Attenuator Plates With Ribbed Bending Support
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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 bending, and can be manufactured using 3D printing for reduced material waste and cost, allowing for high-density features like small openings that shift noise frequencies out of human hearing range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thick plates are used in noise attenuators, then structural strength is improved, but manufacturing cost and difficulty increase, and the plates become prone to bending under pressure-induced loads
Solution Approach 1:
The plate is divided into multiple segments or sections that can be manufactured separately and then assembled. This segmentation allows each section to be thinner and easier to manufacture while the assembled structure provides the necessary structural strength through the combined effect of multiple segments working together.
Solution Approach 2:
The invention employs thin plate structures instead of thick plates, utilizing the inherent flexibility and strength-to-weight ratio of thin structures. The thin plates are designed with appropriate thickness to balance structural integrity under pressure loads while minimizing manufacturing complexity and cost.
2Strength
If thick plates are used in noise attenuators, then structural strength is improved, but frictional losses increase
Solution Approach 1:
The invention uses thin plate structures that reduce the path length for fluid flow through the noise attenuator. This reduction in flow path length directly decreases frictional losses and energy dissipation while the thin plates maintain adequate structural strength through optimized design and material selection.
3Ease of manufacture
If thin plates are used in noise attenuators, then manufacturing cost and complexity are reduced, but the plates become prone to bending under pressure-induced loads
Solution Approach 1:
The plate structure is segmented into multiple sections that are assembled together. This segmentation allows each individual section to remain thin and easy to manufacture, while the assembled configuration provides enhanced structural rigidity and resistance to bending through the distributed support and geometric arrangement of segments.
Solution Approach 2:
The invention may employ composite material structures or combine different materials in the plate construction to achieve high strength-to-thickness ratios. This allows the plates to be thin and easy to manufacture while maintaining adequate resistance to bending under pressure-induced loads through the superior mechanical properties of composite or multi-material constructions.
4Manufacturing precision
If complex manufacturing processes are used, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The invention adopts manufacturing parameters and processes that optimize the balance between precision and productivity. This may include using modern manufacturing techniques such as precision stamping, laser cutting, or additive manufacturing with controlled parameters to achieve the required geometric precision while maintaining high production rates and efficiency.
Data Source
AI summary
Plates and plate assemblies for noise attenuators and other devices and methods of making the same are described herein. An example disc-shaped plate described herein includes a plurality of sector-shaped plates that 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 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.