Patent Description:
Fluid valves, regulators, and other process control devices are commonly distributed throughout process control systems and/or fluid distribution systems to control flow rates and/or pressures of various fluids (e.g., liquids, gases, etc.). Process control devices may be used to change a characteristic of a fluid such as a pressure, a temperature, a flow rate, etc. This change in a characteristic of the fluid often causes a significant amount of audible noise. For instance, fluid regulators are typically used to reduce and/or regulate a pressure of fluid to a predetermined value. Some fluid regulators reduce an inlet pressure to a lower outlet pressure by restricting flow through an orifice to match a downstream demand. However, fluid flowing through the pressure regulators creates a significant amount of audible noise. Therefore, noise attenuators are often coupled to the outlets of pressure regulators. Known noise attenuators include a series of plates with small openings that form flow channels through the plates.

Document <CIT> describes a flow uniformizing baffling for closed process vessels. Fluid flows through a closed process vessel consisting of an inlet section, an intermediate body portion and an outlet section. Intermediate baffles and an effluent baffle keep the flow equalized transversely in their respective regions. Fluid flows through openings and annuli at intermediate and effluent baffles. Baffle plates are supported and attached by screws to a series of circumferential lugs joined to the inner wall of the vessel. Baffles next to a flange joining the intermediate and outlet sections of a shell of the vessel are readily removable for cleaning or adjustment of openings. Lower baffles which must pass through one or more lug circles are cut with a diametrical slit to permit them to be withdrawn in halves for side clearance.

A disc-shape plate for a noise attenuator is according to annexed independent claim <NUM>. Other advantageous features are defined in the dependent claims.

A method to manufacture a disc-shaped plate for a noise attenuator is according to annexed independent claim <NUM>. Other advantageous features are defined in the dependent claims.

Many known process control and/or fluid distribution systems (e.g., power generation systems, petroleum refinery systems, natural gas distribution plants, fuel storage tanks, etc.) employ process control devices or field devices to affect the flow of fluid. For example, pressure regulators are used to control flow rates and/or pressures of various fluids (e.g., liquids, gases, etc.). Known pressure regulators include an inlet that receives fluid from a source at a relatively high pressure and an outlet that provides fluid to downstream equipment at a relatively lower pressure than that of the inlet. The inlet pressure of some known pressure regulators is reduced to a lower outlet pressure by restricting flow through an orifice to match a downstream demand. For example, known pressure regulators of process control and/or fluid distribution systems receive fluid (e.g., gas, liquid) having a relatively high and somewhat variable pressure from an upstream source and regulate the fluid flow to reduce and/or stabilize the pressure to a level suitable for use by downstream equipment (e.g., equipment of a power generator, a petroleum refiner, etc.).

In some instances, process control devices affect the flow of fluid in a manner that creates audible noise. For example, pressure regulators produce a substantial decrease in pressure or flow rate of the fluid, which, in turn, creates a significant amount of audible noise (e.g., greater than about <NUM> decibels). Fluid valves are also known to produce a significant amount of audible noise. Therefore, these process control devices may employ noise attenuators or noise-reduction devices to reduce the level of audible noise created by the fluid flowing through the process control device.

Example noise attenuators are disclosed herein. Noise attenuators include one or more plates or discs disposed in a fluid passageway to induce pressure drops along a flow path through the fluid passageway. The plates include openings (e.g., holes, apertures) that define fluid flow paths through the plates and, thus, through the fluid passageway. As the fluid passes through the plates, the pressure of the fluid is incrementally reduced (e.g., by a discrete amount, by a percentage of the previous fluid pressure) along a flow path. The pressure drops induced by the plates result in a corresponding reduction or attenuation of noise (e.g., by a discrete decibel level, by a percentage of the decibel level otherwise produced by the pressure regulator).

In some instances, these noise attenuators plates are exposed to significant pressure drops across each plate, which can produce relatively high forces on the plates. Such forces on the plates can create high bending stresses that cause the plates to yield. For example, the forces on the plates can cause portions of the plates to bend, deflect, rotate and/or otherwise move away from a wall of the fluid passageway (e.g., in a downstream direction), thereby reducing an amount of noise attenuation provided by the plates.

Therefore, some known plates are relatively thick to withstand the structural loading demands caused by the pressure drops. However, these known thick plates are difficult and costly to manufacture because known thick plates are often machined from large, thick sheets of metal that are cut into the individual plates and drilled (perforated). Further, these known thick plates add significant weight to the noise attenuator, which can complicate transportation, assembly, and installation. Other known plates utilize a central rod that connects to and supports centers of the plates. However, this type of support is susceptible to bending around the peripheral portions of the plate (sometimes referred to as a taco effect). Therefore, the plates still need to be relatively thick to withstand these forces without exhibiting any significant bending. Moreover, conventional machining operations used to produce these known plates are limited in feature density (e.g., the number and size of flow paths that can be formed in a plate in a given area).

Disclosed herein are example plate assemblies that include a thin disc-shaped plate and a support frame for supporting and providing rigidity to the disc-shaped plate. The disc-shaped plate may be coupled (e.g., via one or more threaded fasteners) to the support frame, and the support frame is coupled (e.g., via one or more threaded fasteners) to a body of the attenuator such that the disc-shaped plate is disposed in the fluid passageway of the attenuator body. The support frame is disposed downstream of the disc-shaped plat such that pressure-induced loads on the disc-shaped plate are distributed to the support frame. As such, the support frame prevents or reduces yielding of the disc-shaped plate caused by the pressure drop across the disc-shaped plate. The support frame may be constructed of steel or aluminum, for example. The support frame may include one or more structural members (e.g., ribs, rings, etc.) that provide a relatively large contact area for supporting the disc-shaped plate while still allowing fluid to flow freely through the support frame. As such, the disc-shaped plate can be relatively thin. From an acoustic standpoint, thin plates and thick plates perform similarly. However, from a flow perspective, thin plates produce less frictional losses than thick plates. Further, thin plates are easier and less expensive to manufacture.

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 that builds a 3D object 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 may 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 results in less wasted material than known machining operations. Therefore, 3D printing the disc-shaped plate results in a relatively lower 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 may not be feasible with known machining processes. Smaller diameter openings create noise in higher acoustic frequencies than larger diameter openings. Human hearing is in the range of <NUM>-<NUM>,<NUM> hertz (Hz). Therefore, using smaller diameter openings tends to up-shift the noise frequency to frequencies that are less audible or not audible at all to the human ear.

In some examples, the size of the disc-shaped plate may exceed the printing capabilities of a 3D printer. In particular, the diameter of the disc-shaped plate may be larger than the footprint or building platform of the 3D printer. Therefore, in some examples disclosed herein, the disc-shaped plate is formed by a plurality of sections, such as sectors or angular sections. For example, the disc-shaped plate may be formed by a plurality of sector-shaped plates. Each of the sector-shaped plates may account for a sector of a circle. For example, the disc-shaped plate may be formed by four sector-shaped plates, each forming <NUM>° (i.e., one quarter) of a circle. When the sector-shaped plates are arranged together, the sector-shaped plates form a full circle that defines the disc-shaped plate. In other examples the disc-shaped plate may be divided into more or fewer sector-shaped plates. In some examples, multiple ones of the 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, such that multiple sector-shaped plates can be printed side-by-side during the same print batch. After the sector-shaped plates are constructed, the sector-shaped plates may be coupled to the support frame to form the disc-shaped plate. Using the support frame enables the disc-shaped plate to be formed by one or more sections. In others examples, the disc-shaped plate may be manufactured by conventional machining means (e.g., perforated sheet metal, machined plates, stacked sheet metal, etc.) as a single piece or a plurality of sections.

Also disclosed herein are example disc-shaped plates formed by a plurality of sector-shaped plates that do not utilize support structures (e.g., a support frame) or fasteners (e.g., threaded fasteners). The sector-shaped plates may be arranged together to form a disc-shaped plate that can be disposed in a passageway of a fluid body, such as a noise attenuator body. The disc-shaped plate may be divided into any number of sector-shaped plates (e.g., two, three, four, five, etc.). Each of the 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. When the sector-shaped plates are arranged together, the first mating feature of each of the sector-shaped plates engages or mates with the second mating feature of an adjacent one of the sector-shaped plates. As such, at least a portion of each of the sector-shaped plates overlaps in an axial direction with an adjacent one of the sector-shaped plates. These mating features function to interlock the sector-shaped plates to reduce or prevent bending or axial displacement of the sector-shaped plates under pressure from the fluid flow. These mating features may be designed to prevent axial displacement in the upstream direction, downstream direction, or both. Various differently shaped mating features are disclosed herein.

Once the sector-shaped plates are combined into the disc-shaped plate, the disc-shaped plate may be installed in an attenuator body. In some examples, the outer peripheral region of the disc-shaped plate is clamped between two structures (e.g., an outlet flange of the attenuator body and an inlet flange of a downstream pipe), such that the disc-shaped plate fills or covers the fluid passageway. This clamping prevents radial and axial movement, and the interlocking mating features prevent bending and axial movement of the sector-shaped plates in the fluid passageway. Therefore, no support frames or fasteners are required. This greatly reduces manufacturing costs and assembly time as well as removal or disassembly time.

In some examples, the sector-shaped plates are constructed via 3D printing. In some examples, multiple ones of the 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, such that multiple sector-shaped plates can be printed side-by-side during the same print batch. As disclosed above, 3D printing is advantageous because of the minimal material waste, and because of the high feature density (e.g., thousands of small openings) that can be formed. Further, 3D printing is advantageous to form the mating features on the radial edges, which can be difficult with traditional (subtractive) machining operations. 3D printing may also be used to form complex structures, such as internal lattice structures, within the sector-shaped plates. However, in other examples, the sector-shaped plates may be constructed via traditional (subtractive) machining operations.

While many of the example plates and plate assemblies disclosed herein are described in connection with noise attenuators, it is understood that the example plates and plate assemblies can be used in other devices that that utilize multi-path flow plates. For example, flame arrestors similarly use one or more plates with small openings to allow fluid flow in one direction but prevent or reduce flame flow in the opposite direction. Any of the examples disclosed herein can also be utilized as a flame arrestor plate.

Turning to the figures, <FIG> illustrates an example noise attenuator <NUM> in which the example plates and/or plate assemblies disclosed herein may be implemented. The example noise attenuator <NUM> may be used to reduce noise levels in a process control system and/or fluid distribution system. The example noise attenuator <NUM> may be coupled to, for example, an outlet of a process control device to reduce the noise created by the flow of fluid exiting the process control device.

In the illustrated example of <FIG>, the noise attenuator <NUM> is coupled to a fluid regulator <NUM> (e.g., a pressure regulator) as part of a fluid regulator assembly <NUM>. However, in other examples, the noise attenuator <NUM> may be coupled to and/or otherwise integrated with any other type of process control device (e.g., a valve) and/or any other device that changes a characteristic of a fluid and creates noise. In the illustrated example, the fluid regulator assembly <NUM> is to process a fluid (e.g., natural gas, air, propane, nitrogen, hydrogen, carbon dioxide, etc.) through a passageway of the fluid regulator <NUM> between a regulator inlet <NUM> and a regulator outlet <NUM>. In this example, the regulator inlet <NUM> receives fluid from an upstream pipe <NUM>. The regulator <NUM> receives the fluid at a relatively high pressure (e.g., a few hundred pounds-per-square-inch (psi), between approximately <NUM> psi and <NUM> psi, etc.) at the regulator inlet <NUM> and reduces the pressure of the fluid at the regulator outlet <NUM> (e.g., down to about <NUM> psi, a few hundred psi, to a pressure that is just below the inlet pressure, etc.) based on a predetermined or preset setting. Due to relatively large pressure drops of the fluid as the fluid flows between the regulator inlet <NUM> and the regulator outlet <NUM> and/or relatively high velocity fluid flow rate of the fluid exiting the regulator outlet <NUM>, the fluid may generate unacceptable noise levels (e.g., greater than <NUM> decibels).

The example noise attenuator <NUM> is in fluid communication with the regulator outlet <NUM> and reduces the noise levels produced by the fluid regulator <NUM> to an acceptable level (e.g., lower than <NUM> decibels). In this example, the noise attenuator <NUM> is coupled directly to the regulator outlet <NUM>. However, in other examples, a pipe may be disposed between the regulator outlet <NUM> and the noise attenuator <NUM>. The fluid exits the regulator outlet <NUM> and flows through the noise attenuator <NUM>. The noise attenuator <NUM> is coupled to a downstream pipe <NUM>, which transfers the fluid to a downstream location.

<FIG> is a perspective cross-sectional view of the example noise attenuator <NUM>. In the illustrated example, the noise attenuator <NUM> includes a fluid body <NUM> defining a fluid passageway <NUM> between an inlet <NUM> and an outlet <NUM>. The body <NUM> has an inlet flange <NUM> at the inlet <NUM> to be coupled (e.g., via threaded fasteners) to the regulator outlet <NUM> (<FIG>). The body <NUM> also has an outlet flange <NUM> at the outlet <NUM> to be coupled (e.g., via threaded fasteners) to an inlet flange <NUM> of the downstream pipe <NUM>. The noise attenuator <NUM> includes one or more structure(s) to reduce noise of fluid flowing through the fluid passageway <NUM>.

In the illustrated example, the noise attenuator <NUM> includes an example plate assembly <NUM> constructed in accordance with the teachings of this disclosure. The plate assembly <NUM> is coupled to the body <NUM>. The example plate assembly <NUM> includes an example disc-shaped plate <NUM> and an example support frame <NUM>. The disc-shaped plate <NUM> is disposed in the fluid passageway <NUM> and supported by the support frame <NUM>. A diameter of the disc-shaped plate <NUM> is oriented perpendicular to a central axis <NUM> of the fluid passageway <NUM>. The disc-shaped plate <NUM> has substantially the same diameter as and/or otherwise fills the portion of the fluid passageway <NUM> where the plate assembly <NUM> is disposed. The disc-shaped plate <NUM> affects a flow of fluid through the body <NUM> to reduce audible noise.

The disc-shaped plate <NUM> includes openings (e.g., apertures, perforations, etc.) that define flow paths through the disc-shaped plate <NUM> and, thus, through the fluid passageway <NUM>. The openings are referenced in further detail in <FIG>. Fluid is to flow from an upstream source (e.g., from the regulator outlet <NUM>) into the inlet <NUM>, through the disc-shaped plate <NUM> in the fluid passageway <NUM>, and through the outlet <NUM> to the downstream pipe <NUM>. The disc-shaped plate <NUM> induces 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 <NUM> reduces audible noise caused by high energy fluid flowing through a fluid passageway of a process control device (e.g., the fluid regulator <NUM> of <FIG>) and/or the fluid passageway <NUM> of the noise attenuator <NUM> of a fluid regulator assembly (e.g., the fluid regulator assembly <NUM> of <FIG>).

In the illustrated example, the disc-shaped plate <NUM> is supported in the fluid passageway <NUM> by the support frame <NUM>. The support frame <NUM> has a flange <NUM>. In some examples, the flange <NUM> is configured to be coupled between the outlet flange <NUM> and the inlet flange <NUM>. In the illustrated example, the flange <NUM> is disposed in a recess <NUM> formed in a face <NUM> of the outlet flange <NUM>. In some examples, the flange <NUM> is coupled to the body <NUM> via threaded fasteners (e.g., bolts, screws, etc.). When the inlet flange <NUM> of the downstream pipe <NUM> is coupled to the outlet flange <NUM> of the noise attenuator <NUM>, the flange <NUM> is clamped between the outlet flange <NUM> and the inlet flange <NUM>. In the illustrated example, the support frame <NUM> is disposed downstream of the disc-shaped plate <NUM> in the fluid passageway <NUM>. The support frame <NUM> prevents or reduces bending in the disc-shaped plate <NUM> that may be caused by the pressure drop across the disc-shaped plate <NUM>. As such, the disc-shaped plate <NUM> can be relatively thin, which results in less frictional losses than thicker plates.

In the illustrated example, a portion of the fluid passageway <NUM> is angled or tapered between the inlet <NUM> and the outlet <NUM>. This diverging shape of the fluid passageway <NUM> enables the fluid to expand and decrease in velocity to dissipate energy of the fluid flow and/or to reduce noise. In other examples, the fluid passageway <NUM> may not be tapered.

In this example, the plate assembly <NUM> is coupled to the body <NUM> at or near the outlet <NUM>. In some examples, this position of a plate or plate assembly is referred as an end plate. In other examples, the plate assembly <NUM> may be coupled to the body <NUM> such that the plate assembly <NUM> is disposed in another location within the fluid passageway <NUM> (e.g., closer to the inlet <NUM>).

In the illustrated example, the noise attenuator <NUM> includes additional plates <NUM>, <NUM> (sometimes referred to as internal plates) disposed in the fluid passageway <NUM> upstream of the plate assembly <NUM>. The plate <NUM> is engaged with a ledge <NUM> in the fluid passageway <NUM>. The plate <NUM> may be installed from the inlet <NUM>, and the plate <NUM> may be installed from the outlet <NUM>. The plates <NUM>, <NUM> are coupled via a plurality of rods <NUM> (one of which is referenced in <FIG>), which provide support to prevent or reduce bending of the plates <NUM>, <NUM>. The plates <NUM>, <NUM> include openings defining flow paths through the respective plates <NUM>, <NUM> to attenuate noise. The plates <NUM>, <NUM> incrementally slow and reduce noise of the flow fluid. In this example, the rods <NUM> are not coupled to the plate assembly <NUM>. Thus, in this example, the plate assembly <NUM> (e.g., the end plate) is not coupled to the plates <NUM>, <NUM> (e.g., the internal plates). In other examples, the rods <NUM> may extend to and be coupled to the plate assembly <NUM>. Additionally or alternatively, in some examples one or more spacers may be disposed between and in contact with the second plate <NUM> and the disc-shaped plate <NUM>. In such an example, the spacer(s) would transfer loads from the plates <NUM>, <NUM> to the plate assembly <NUM>. In other examples, the noise attenuator <NUM> may include more or fewer internal plates. In some examples, the noise attenuator <NUM> may not include any internal plates, such that the disc-shaped plate <NUM> is the only plate implemented in the noise attenuator <NUM>.

<FIG> is a perspective view of the example plate assembly <NUM> including the disc-shaped plate <NUM> and the support frame <NUM>. In the illustrated example, the support frame <NUM> has a body <NUM>, which is a ring. The disc-shaped plate <NUM> may be coupled to the body <NUM> of the support frame <NUM>. In this example, the disc-shaped plate <NUM> is coupled to the body <NUM> of the support frame <NUM> via threaded fasteners <NUM> (e.g., bolts, screws, etc.) (one of which is referenced in <FIG>). Any number of threaded fasteners may be used. As such, the disc-shaped plate <NUM> is removably coupled to the support frame <NUM>. In other examples, the disc-shaped plate <NUM> may be coupled to the support frame <NUM> via other chemical and/or mechanical fastening techniques (e.g., press fitted joints, welded joints, adhesives, etc.).

The flange <NUM> extends outward from the body <NUM>. The flange is to be coupled to the body <NUM> (<FIG>) of the noise attenuator <NUM> (<FIG>) to dispose the disc-shaped plate <NUM> in the fluid passageway <NUM> (<FIG>). The flange <NUM> has openings <NUM> to receive threaded fasteners <NUM> (e.g., bolts, screws, etc.) (one of which is referenced in <FIG>) for coupling the support frame <NUM> to the body <NUM>.

In the illustrated example, the disc-shaped plate <NUM> is formed by a plurality of sector-shaped plates. In this example, the disc-shaped plate <NUM> is formed by three sector-shaped plates, including a first sector-shaped plate <NUM>, a second sector-shaped plate <NUM>, and a third sector-shaped plate <NUM>. The sector-shaped plates <NUM>-<NUM> form the disc-shaped plate <NUM> when arranged next to each other. In this example, each of the sector-shaped plates <NUM>-<NUM> is a <NUM>° sector of a circle. As such, when the sector-shaped plates <NUM>-<NUM> are arranged together, the sector-shaped plates <NUM>-<NUM> form a full <NUM>° circle. In some examples, when the sector-shaped plates <NUM>-<NUM> are coupled to the support frame <NUM>, the radial edges of the sector-shaped plates <NUM>-<NUM> may be in contact with each other. In other examples, the radial edges may be spaced apart from each other.

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

In this example, each of the sector-shaped plates <NUM>-<NUM> is the same, i.e., is the same shape and size. As such, the disc-shaped plate <NUM> can be easily manufactured by constructing three of the same part, as opposed to requiring differently shaped parts to be manufactured. In other examples, one or more of the sector-shaped plates may be different than the other plates. For example, two of the sector-shaped plates may be <NUM>° sectors, and the third sector-shaped plate may be an <NUM>° sector.

Each of the sector-shaped plates <NUM>-<NUM> includes a plurality of openings <NUM> (one of which is reference on each of the sector-shaped plates <NUM>-<NUM>). The openings <NUM> form flow paths through the respective sector-shaped plates <NUM>-<NUM> to attenuate noise. When the plate assembly <NUM> is disposed in the fluid passageway <NUM> (<FIG>), the fluid flows through the openings <NUM>, which reduces or attenuates noise. The openings <NUM> may have a relatively small cross-sectional size or diameter (e.g., less than <NUM> diameter). In some examples, all of the openings <NUM> are the same cross-sectional size or diameter. In some examples, certain ones of the openings <NUM> may have different cross-sectional sizes or diameters. The support frame <NUM> has one or more openings behind the disc-shaped plate <NUM>, which are shown in further detail in connection with <FIG>. In the illustrated example, the openings <NUM> are grouped together into sections or groups that align with the openings in the support frame <NUM>. In some examples, the openings <NUM> within each of the groups are spaced equidistant from each other.

<FIG> shows the plate assembly <NUM> of <FIG> in which the second and third sector-shaped plates <NUM>, <NUM> and the threaded fasteners <NUM>, <NUM> have been removed. Only the first sector-shaped plate <NUM> is shown on the support frame <NUM>. As shown in <FIG>, the body <NUM> of the support frame <NUM> includes a plurality of openings <NUM> (one of which is referenced in <FIG>). The openings <NUM> have a larger cross-sectional area than the openings <NUM> in the disc-shaped plate <NUM>. The openings <NUM> are formed by one or more structural members extending across the body <NUM>. For example, as shown in <FIG>, the support frame <NUM> has a plurality of radially extending ribs <NUM> (one of which is referenced in <FIG>) and a plurality of rings <NUM> (one of which is referenced in <FIG>). The arrangement of the ribs <NUM> and the rings <NUM> defines the openings <NUM> through the body <NUM>. The ribs <NUM> and the rings <NUM> provide a large area for supporting the disc-shaped plate <NUM> to prevent or reduce bending of the disc-shaped plate <NUM>. In particular, the ribs <NUM> and the rings <NUM> create a larger contact area that distributes pressure-induced loads on the disc-shaped plate <NUM> to the support frame <NUM>, which is a thicker, more rigid structure. The total contact area can be sized based on the flow needs and the support needs. In general, less contact area between the disc-shaped plate <NUM> and the support frame <NUM> increases the available flow area. However, more contact area between the disc-shaped plate <NUM> and the support frame <NUM> reduces the plate thickness requirements. In other examples, the support frame <NUM> may not include any rings. Instead, the support frame <NUM> may only include one or more ribs. While in this example the disc-shaped plate <NUM> is in contact with the support frame <NUM>, in other examples, one or more spacers may be provided between the disc-shaped plate <NUM> and the support frame <NUM>.

The support frame <NUM> is constructed of a rigid material. For example, the support frame <NUM> may be constructed of steel (e.g., carbon steel, stainless steel, etc.). In other examples, the support frame <NUM> may be constructed of another material, such as aluminum. In some examples, the support frame <NUM> is constructed via an extrusion process. In other examples, the support frame <NUM> may be constructed of other materials and/or other manufacturing techniques (e.g., 3D printing). In some examples, the support frame <NUM>, including the flange <NUM>, the body <NUM>, the ribs <NUM>, and the rings <NUM>, is constructed to be a single unitary part or component. In other examples, the support frame <NUM> may be constructed of multiple parts that are coupled together (e.g., via fasteners, welding, etc.).

As described above, the openings <NUM> in the disc-shaped plate <NUM> may form groups that align with the openings <NUM> in the support frame <NUM>. Therefore, the openings <NUM> are not formed throughout the entire disc-shaped plate <NUM>. In some examples, this reduces manufacturing time and costs. For example, this may reduce the amount of time spent drilling or printing (e.g., via a 3D printer) the openings <NUM>. In other examples, the openings <NUM> may be disposed in other locations. In some examples, the entire disc-shaped plate <NUM> is formed with openings.

In some examples, one or more of the threaded fasteners <NUM> (<FIG>) may be used to couple two of the sector-shaped plates <NUM>-<NUM> to the support frame <NUM>. This reduces the number of threaded fasteners used to couple the sector-shaped plates <NUM>-<NUM> to the support frame <NUM>. For example, as shown in <FIG>, the first sector-shaped plate <NUM> has a first radial edge <NUM>. The first radial edge <NUM> has three grooves <NUM> (one of which is referenced in <FIG>). Each of the grooves <NUM> forms half of a fastener bore. The corresponding radial edge on the third sector-shaped plate <NUM> (<FIG>) has matching grooves that form the other halves of the fastener bores. When the third sector-plate <NUM> is disposed next to the first sector-shaped plate <NUM>, the grooves form fastener bores. The threaded fasteners <NUM> (<FIG>) extend through the fastener bores and into bores <NUM> (one of which is referenced in <FIG>) formed in the support frame <NUM>.

<FIG> shows a cross-sectioned region of the support frame <NUM>. The threaded fasteners <NUM> (one of which is referenced in <FIG>) couple the first sector-shaped plate <NUM> to the support frame <NUM>. The threaded fasteners <NUM> extend through the grooves <NUM> (one of which is referenced in <FIG>) in the first sector-shaped plate <NUM> and into corresponding bores <NUM> (one of which is referenced is <FIG>) in the support frame <NUM>. In this example, the bores <NUM> in the support frame <NUM> are threaded, but the grooves <NUM> in the first sector-shaped plate <NUM> are not threaded. The second and third sector-shaped plate <NUM>, <NUM> may be similarly structured and coupled to the support frame <NUM>. In other examples, one or more of the grooves <NUM> in the first, second, and/or third sector-shaped plates <NUM>-<NUM> may be threaded.

As disclosed above, in some examples, the sector-shaped plates <NUM>-<NUM> are constructed via 3D printing. For example, the sector-shaped plates <NUM>-<NUM> may be constructed by a 3D printer. Therefore, each of the sector-shaped plates <NUM>-<NUM> is constructed via layers of fused material (e.g., metal). 3D printing is advantageous because it can be used to form plates with high density features, such as thousands of small flow paths. Further, 3D printing enables the formation of small features, such as the openings <NUM>. As such, the openings <NUM> can be sized smaller than openings formed with known machining techniques.

In some examples, the disc-shaped plate <NUM> is formed by multiple sections because of part processing size limits of known 3D printers. In particular, the diameter of the disc-shaped plate <NUM> may be relatively large, such as three feet in diameter. Such a large diameter plate may be too large to construct in a typical 3D printer. Therefore, the disc-shaped plate is divided into smaller pieces, i.e., the sector-shaped plates <NUM>-<NUM>, which are smaller and can be constructed in the 3D printer. However, if the disc-shaped plate <NUM> is capable of being printed in one piece in a 3D printer, then the disc-shaped plate <NUM> can be printed as a single unitary piece. In some examples, the disc-shaped plate <NUM> is printed via a 3D printer, while the other plates of the noise attenuator <NUM> (e.g., the plates <NUM>, <NUM>) are constructed via traditional machine operations. In other examples, the other plates can also be 3D printed.

<FIG> shows an example 3D printer <NUM> that may be used to print the sector-shaped plates <NUM>-<NUM>. In some examples, the sector-shaped plates <NUM>-<NUM> are printed in a vertical orientation starting from a radial edge or end of the sector-shaped plates <NUM>-<NUM>. This enables multiple sector-shaped plates to be constructed simultaneously in a single print batch. For example, as shown in <FIG>, the sector-shaped plates <NUM>-<NUM> can be constructed side-by-side during the same print batch. As such, the entire disc-shaped plate <NUM> can be constructed via the 3D printer <NUM>.

In this example, each of the sector-shaped plates <NUM>-<NUM> is the same, i.e., is the same shape and size. As such, three of the same part model may be printed via the printer <NUM>. The sector-shaped plates <NUM>-<NUM> may be constructed of any material capable of being printed by a 3D printer. In some examples, the sector-shaped plates <NUM>-<NUM> are constructed of carbon steel, <NUM> stainless steel, aluminum, and/or titanium. In other examples, the sector-shaped plates <NUM>-<NUM> may be constructed of other materials. In some examples, additives or other components are added to make a raw material printable via 3D printing. Using 3D printing, the thickness of the sector-shaped plates <NUM>-<NUM> can be the same or varied depending on the desired application.

In some examples, the sector-shaped plates <NUM>-<NUM> are printed simultaneously in the same 3D printer during the same print batch. In other examples, the sector-shaped plates <NUM>-<NUM> may be formed by the same 3D printer during separate print batches. In still other examples, the sector-shaped plates <NUM>-<NUM> may be formed by different printers at the same time or different times.

In some examples, the disc-shaped plate <NUM> is constructed via 3D printing, while the support frame <NUM> is constructed via traditional machining techniques (e.g., extruding, drilling, laser cutting, water jet cutting, etc.). In other examples, the support frame <NUM> may also be constructed via 3D printing. For example, the support frame <NUM> may be constructed in the 3D printer <NUM>.

Because 3D printing involves building layer upon layer of material, 3D printing has limitations with respect to overhung surfaces. Most 3D printers have a critical angle, such as <NUM>°. Any surface that is to be angled beyond that critical printing angle may require temporary supports. Otherwise, the material may yield or fall apart while printing.

For example, because the sector-shaped plates <NUM>-<NUM> are printed vertically, the openings <NUM> may not be formed as circular. <FIG> shows an enlarged view of one of the openings <NUM> formed in the first sector-shaped plate <NUM>. As shown, the opening <NUM> is tear-dropped shape. The upper part of the opening <NUM> is printed at the maximum allowable angle, which may be <NUM>°, for example. This results in a tear-dropped shaped opening. The other openings <NUM> may be similarly shaped. This tear-dropped shaped opening does not adversely affect the flow of fluid through the openings <NUM>.

In other examples, the openings <NUM> may be shaped differently. For example, if the disc-shaped plate <NUM> is printed in a horizontal orientation, the openings may be formed as circular or round, as shown in <FIG>. In still other examples, the openings <NUM> may have a different shape (e.g., hexagonal, polygonal). The flow paths created by the openings <NUM> may be axially straight, overlapped, rotated, or twisted. In some examples, all of the openings <NUM> are identical. In other examples, the openings <NUM> may have different diameters and/or different shapes. The distances between adjacent openings <NUM> can be the same or can be varied within the disc-shaped plate <NUM> or within the same noise attenuator.

In other examples, the disc-shaped plate <NUM>, formed as a single piece or by a plurality sector-shaped plates, may be constructed by traditional (subtractive) manufacturing operations. For example, the disc-shaped plate <NUM> and/or the sector-shaped plates <NUM>-<NUM> may be perforated sheet metal, a machined plate, stacked sheet metal, etc. Therefore, the disc-shaped plate <NUM> may be constructed from a single piece of perforated sheet metal, stacked perforated sheet metal (e.g., coupled via threaded fasteners), sections of perforated sheet metal, 3D printed units (e.g., constructed of metal or plastic), 3D printed whole or sectional units, and/or single or sectional machined parts (single or sectional). In some examples, the disc-shaped plate <NUM> and the support frame <NUM> are constructed of a single unitary part or component. For example, the entire plate assembly <NUM> may be printed as a single part. While in the illustrated examples above only one disc-shaped plate is coupled to the support frame <NUM>, in other examples, multiple disc-shaped plates may be stacked and coupled to the support frame <NUM>. The disc-shaped plates may be coupled via threaded fasteners. In some examples, such as where high back-pressure is experienced, a second support frame may be disposed upstream of the disc-shaped plate <NUM>. Therefore the disc-shaped plate <NUM> may be clamped between two support frames.

<FIG> is a perspective view of the example support frame <NUM>. As disclosed above, the support frame <NUM> may be constructed of a single unitary part or component, or the support frame <NUM> may be constructed of multiple parts that are coupled together. As disclosed above, the support frame <NUM> has an arrangement of structural members (e.g., the ribs <NUM> and the rings <NUM>) to support the disc-shaped plate <NUM> (<FIG> and <FIG>) in the fluid passageway <NUM> (<FIG>) while also allowing fluid flow through the support frame <NUM>. The support frame <NUM> may have other arrangements or layouts of the structural members.

For example, <FIG> is an end view of another example support frame <NUM> that may be used in place of the support frame <NUM>. The support frame <NUM> has an arrangement of structural members to support the disc-shaped plate <NUM>. <FIG> is a perspective view of another example support frame <NUM> that may be used in place of the support frame <NUM>. The support frame <NUM> has an arrangement of structural members to support the disc-shaped plate <NUM>. <FIG> is an end view of another example support frame <NUM> that may be used in place of the support frame <NUM>. The support frame <NUM> has an arrangement of structural members to support the disc-shaped plate <NUM>. The size, thickness, and arrangement of the structural members may have an effect on strength and flow efficiency of a support frame. For example, the support frame <NUM> may have better flow than the support frame <NUM> because the support frame <NUM> has less structure in the center. However, the support frame <NUM> may be stronger than the support frame <NUM> because of the increased structure in the center and, thus, can be sized thinner than the support frame <NUM>. As another example, the support frame <NUM> may have better flow than the support frame <NUM>, but the support frame <NUM> may be weaker than the support frame <NUM> because the support frame <NUM> does not have the center ring as in the support frame <NUM>.

<FIG> are perspective views of an example cartridge <NUM> (which may also be referred to as a silencer assembly) that may be used to attenuate noise of fluid flow in a fluid body. For example, the cartridge <NUM> may be installed in the fluid passageway <NUM> (<FIG>) of the noise attenuator <NUM> (<FIG>) in addition to or as an alternative to the other plates. The example cartridge <NUM> includes multiple plate assemblies forming multiple noise attenuation stages.

In the illustrated example, the cartridge <NUM> includes a first plate assembly <NUM> including a first disc-shaped plate <NUM> for attenuating noise. The first disc-shaped plate <NUM> has a plurality of openings <NUM> (one of which is referenced in <FIG>) forming flow paths through the first disc-shaped plate <NUM>. The first disc-shaped plate <NUM> is coupled to and/or otherwise supported by a first support frame <NUM>, which operates similar to the support frame <NUM> disclosed above. When the cartridge <NUM> is disposed in a fluid body, the first support frame <NUM> is disposed downstream of the first disc-shaped plate <NUM>. The first support frame <NUM> has a plurality of radially extending ribs <NUM>. Any number of ribs may be employed. The first support frame <NUM> prevents or reduces bending of the first disc-shaped plate <NUM> caused by pressure differential across the first disc-shaped plate <NUM>. As such, the first disc-shaped plate <NUM> can be sized relatively thin compared known noise attenuator plates, because the first disc-shaped plate <NUM> does not require the structural rigidity to withstand the pressure differential. Such a thin plate is easier and less expensive to manufacture.

In some examples, the cartridge <NUM> includes one or more additional plate assemblies for attenuating noise. For example, as shown in <FIG>, the cartridge <NUM> includes a second plate assembly <NUM> including a second disc-shaped plate <NUM> and a third plate assembly <NUM> including a third disc-shaped plate <NUM>. Each of the second and third disc-shaped plates <NUM>, <NUM> has a plurality of openings forming flow paths. The second disc-shaped plate <NUM> is coupled to and/or otherwise supported by a second support frame <NUM>. The third disc-shaped plate <NUM> is coupled to and/or otherwise supported by a second support frame <NUM>. In other examples, the cartridge <NUM> may include more than three plate assemblies.

In some examples, the first, second, and third disc-shaped plates <NUM>, <NUM>, <NUM> are coupled to the respective first, second, and third support frames <NUM>, <NUM>, <NUM> frames via threaded fasteners. In other examples, the first, second, and third disc-shaped plates <NUM>, <NUM>, <NUM> may be coupled to the respective first, second, and third support frames <NUM>, <NUM>, <NUM> using other chemical and/or mechanical fastening techniques.

In the illustrated example, the first, second, and third plate assemblies <NUM>, <NUM>, <NUM> are coupled to and spaced apart along a central rod <NUM>. The central rod <NUM> is coupled to and extends from a base <NUM>. To install the cartridge <NUM> in a fluid body, the base <NUM> may be coupled to the fluid body so that the first, second, and third plate assemblies <NUM>, <NUM>, <NUM> are disposed downstream of the base <NUM>. For example, the base <NUM> may be coupled to the body <NUM> of the noise attenuator <NUM> near the inlet <NUM>, such that the first, second, and third plate assemblies <NUM>, <NUM>, <NUM> are disposed in the fluid passageway <NUM>.

In this example, the first, second, and third disc-shaped plates <NUM>, <NUM>, <NUM> are perforated plates. The first, second, and third disc-shaped plates <NUM>, <NUM>, <NUM> may be constructed via a machining process. In other examples, the first, second, and/or third disc-shaped plates <NUM>, <NUM>, <NUM> may be constructed via other manufacturing processes. In some examples, the first, second, and/or third disc-shaped plates <NUM>, <NUM>, <NUM> are constructed via 3D printing (e.g., by the 3D printer <NUM> of <FIG>). In this example, each of the first, second, and third disc-shaped plates <NUM>, <NUM>, <NUM> is a single unitary part or component. In other examples, any of the first, second, and/or third disc-shaped plates <NUM>, <NUM>, <NUM> may be constructed of two or more sector-shaped plates as disclosed in other examples herein.

In some examples, the support frames <NUM>, <NUM>, <NUM> are constructed via an extrusion process. For example, a cylinder of material may be extruded into the shape of the support frames <NUM>, <NUM>, <NUM>. Then, the cylinder may be cut into sections to form the individual support frames <NUM>, <NUM>, <NUM>. The support frames <NUM>, <NUM>, <NUM> can be cut to the size (length) according to specific application loading requirements. As shown in <FIG>, the first support frame <NUM> is a double frame compared to the second and third support frames <NUM>, <NUM>. Any number of support frames may be used in each of the plate assemblies <NUM>, <NUM>, <NUM>. In other examples, the support frames <NUM>, <NUM>, <NUM> can be constructed using other manufacturing processes, such as 3D printing.

In some examples, the disc-shaped plates <NUM>, <NUM>, <NUM> are the same diameter as their associated support frames <NUM>, <NUM>, <NUM>. In other examples, any of the disc-shaped plates <NUM>, <NUM>, <NUM> may be larger than their associated support frames <NUM>, <NUM>, <NUM>. For example, as shown in <FIG>, the first disc-shaped plate <NUM> has a larger diameter than the first support frame <NUM>. The disc-shaped plates <NUM>, <NUM>, <NUM> are sized to substantially fill the fluid passageway in which the respective disc-shaped plates <NUM>, <NUM>, <NUM> are to be disposed.

<FIG> is an end view of the cartridge <NUM> showing the first disc-shaped plate <NUM> and the first support frame <NUM>. <FIG> is a side view the cartridge <NUM>. As shown in <FIG>, the plate assemblies <NUM>, <NUM>, <NUM> are coupled to the central rod <NUM>. In some examples, more than one rod may be used to connect the plate assemblies <NUM>, <NUM>, <NUM>. In the illustrated example, the plate assemblies <NUM>, <NUM>, <NUM> are spaced apart from each other by spacers <NUM>. The plate assemblies <NUM>, <NUM>, <NUM> may be spaced apart any desired distance. In some examples, the spacers <NUM> are constructed via an extrusion process. In other examples, the plate assemblies <NUM>, <NUM>, <NUM> may not be spaced apart. Instead, the plate assemblies <NUM>, <NUM>, <NUM> may be stacked or disposed adjacent (e.g., in contact) with each other.

The width of the structural members (e.g., the ribs <NUM>) and the axial length of the support frames <NUM>, <NUM>, <NUM> may be changed depending on the desired application. For example, a user that desires increased flow may use a support frame with thinner ribs but a lager axial length. In another example, a user that desires significant noise reeducation may use a noise attenuator with multiple stages, where each stage supports a small pressure drop, as compared to a noise attenuator with fewer stages.

<FIG> is a flowchart representative of an example method <NUM> of manufacturing a disc-shaped plate and installing the disc-shaped plate in a fluid body of a noise attenuator. The example method <NUM> may be used to manufacture and install any of the example disc-shaped plates disclosed herein having multiple plate sections or sectors.

At block <NUM>, the example method <NUM> includes printing, via a 3D printer, a plurality of sector-shaped plates. For example, as shown in <FIG>, the first, second, and third sector-shaped plates <NUM>-<NUM> are printed via the 3D printer <NUM>. The sector-shaped plates <NUM>-<NUM> include the openings <NUM> that form flow paths. Each of the sector-shaped plates <NUM>-<NUM> may be the same size (e.g., each being <NUM>° sector) or different sizes. In some examples, each of the sector-shaped plates <NUM>-<NUM> is printed in a vertical orientation. This enables multiple sector-shaped plates to be printed side-by-side in the same print batch. Therefore, the sector-shaped plates <NUM>-<NUM> may be printed simultaneously as part of the same print batch. In some examples, one or more post-machining operations (e.g., drilling, cutting, sanding, etc.) may be performed to smooth the surfaces of the sector-shaped plates <NUM>-<NUM>.

At block <NUM>, the example method <NUM> includes coupling the plurality of sector-shaped plates to a support frame. For example, as shown in <FIG>, the sector-shaped plates <NUM>-<NUM> are coupled to the support frame <NUM>. In some examples, the sector-shaped plates <NUM>-<NUM> are coupled to the support frame <NUM> via the threaded fasteners <NUM>. In some examples, one or more of the threaded fasteners <NUM> couple two of the sector-shaped plates <NUM>-<NUM> to the support frame <NUM>.

At block <NUM>, the example method <NUM> includes coupling the support frame to a fluid body such that a disc-shaped plate formed by the plurality of sector-shaped plates is disposed in a fluid passageway of the fluid body. For example, as shown in <FIG>, the support frame <NUM> is coupled to the body <NUM> of the noise attenuator <NUM> such that the disc-shaped plate <NUM> is disposed in the fluid passageway <NUM>. The support frame <NUM> may be coupled to the body <NUM> via the threaded fasteners <NUM>. In other examples, if the disc-shaped plate <NUM> is small enough to be printed as one piece in a 3D printer, the entire disc-shaped plate <NUM> may be printed as a single plate, which may then be coupled to the support frame <NUM> and disposed in the fluid passageway <NUM>.

If a plate is not constructed of multiple plate sectors or sections, the plate may be manufactured as a single-piece plate via 3D printing or by other traditional manufacturing process (e.g., laser cutting, water jet cutting, drilling, etc.) and similarly coupled to a support frame. For example, the disc-shaped plates <NUM>, <NUM>, <NUM> in <FIG> are single-piece plates. The disc-shaped plates <NUM>, <NUM>, <NUM> may be machined plates. The disc-shaped plates <NUM>, <NUM>, <NUM> are coupled to the respective support frames <NUM>, <NUM>, <NUM>, which are then coupled (as a cartridge) to and/or otherwise disposed in a fluid passageway of a fluid body.

In some of the examples disclosed above, the disc-shaped plate is supported by a support frame. Also disclosed herein are examples in which a support frame is not used. <FIG> is a perspective view of an example disc-shaped plate <NUM> constructed in accordance with the teachings of this disclose. The example disc-shaped plate <NUM> may be used in a noise attenuator to reduce noise of the flowing fluid. The example disc-shaped plate <NUM> is designed such that neither a support structure nor fasteners are utilized.

In the illustrated example, the disc-shaped plate <NUM> is formed or defined by a plurality of sector-shaped plates. In particular, in this example, the disc-shaped plate <NUM> includes a first sector-shaped plate <NUM>, a second sector-shaped plate <NUM>, a third sector-shaped plate <NUM>, and a fourth sector-shaped plate <NUM>. The sector-shaped plates <NUM>-<NUM>, when arranged together, form the disc-shaped plate <NUM>. In this example, each of the sector-shaped plates <NUM>-<NUM>, when arranged together, forms a <NUM>° sector of a circle. In other examples, the disc-shaped plate <NUM> may be formed by more or fewer sector-shaped plates. For example, the disc-shaped plate <NUM> may be formed by five sector-shaped plates (e.g., each forming <NUM>° of a circle), six sector-shaped plates (e.g., each forming <NUM>° of a circle), etc. In this example, each of the sector-shaped plates <NUM>-<NUM> is the same, i.e., forms <NUM>° of the disc-shaped plate <NUM>. In other examples, one or more of the sector-shaped plates <NUM>-<NUM> may be sized differently. For example, three of the sector-shaped plates may each form <NUM>° of the disc-shaped plate <NUM>, while the fourth sector-shaped plate may form <NUM>° of the disc-shaped plate <NUM>.

Each of the sector-shaped plates <NUM>-<NUM> has a plurality of openings <NUM> (one of which is referenced in connection with the first sector-shaped plate <NUM> in <FIG>) extending through the respective sector-shaped plates <NUM>-<NUM>. The openings <NUM> form flow paths through the respective sector-shaped plates <NUM>-<NUM> to attenuate noise. The disc-shaped plate <NUM> has a first side <NUM>, a second side <NUM> opposite the first side <NUM>, and an outer peripheral edge <NUM>. When the disc-shaped plate <NUM> is installed in a fluid body, one of the sides <NUM>, <NUM> faces upstream and one of the sides <NUM>, <NUM> faces downstream.

In some examples, the sector-shaped plates <NUM>-<NUM> are constructed via a 3D printing process. For example, the sector-shaped plates <NUM>-<NUM> may be printed by the printer <NUM> of <FIG>. Therefore, each of the sector-shaped plates <NUM>-<NUM> is constructed via layers of fused material (e.g., metal). In some examples, the diameter of the disc-shaped plate <NUM> may be larger than the printing capacity of a 3D printer. Therefore, printing the individual sector-shaped plates <NUM>-<NUM> enables the disc-shaped plate <NUM> to be constructed via 3D printing. As disclosed above, 3D printing enables the formation of extremely small openings. Further, as compared to machining processes, 3D printing wastes minimal material. In this example, each of the sector-shaped plates <NUM>-<NUM> is the same, i.e., is the same shape and size. As such, four of the same sector-shaped plate can be manufactured using the same print model, which makes manufacturing and assembly easier.

<FIG> shows the sector-shaped plates <NUM>-<NUM> as separated. The sector-shaped plates <NUM>-<NUM> may be pushed together to form the disc-shaped plate <NUM>. For example, the sector-shaped plates <NUM>-<NUM> may be laid on a flat surface and pushed radially inward toward each other.

Each of the sector-shaped plates <NUM>-<NUM> mates or interlocks with the two adjacent sector-shaped plates <NUM>-<NUM>. For example, the first sector-shaped plate <NUM> has a first radial edge <NUM>, a second radial edge <NUM>, and a peripheral edge <NUM>. The first radial edge <NUM> forms or includes a first mating feature <NUM> and the second radial edge <NUM> forms or includes a second mating feature <NUM> that is complementary to the first mating feature <NUM>. The mating features <NUM>, <NUM> may also be referred to as locking features. The mating features <NUM>, <NUM> may be male and female shaped features. In this example, the first mating feature <NUM> is an angled underhang, and the second mating feature <NUM> is an angled overhang that is complementary to or opposite of the first mating feature <NUM>. The second, third, and fourth sector-shaped plates <NUM>-<NUM> are the same as the first sector-shaped plate <NUM>. When the sector-shaped plates <NUM>-<NUM> are assembled into the disc-shaped plate <NUM>, the first mating feature <NUM> of each of the sector-shaped plates <NUM>-<NUM> engages or mates with the second mating feature <NUM> of an adjacent one of the sector-shaped plates <NUM>-<NUM>. Therefore, the first mating feature <NUM> of the first sector-shaped plate <NUM> mates with the second mating feature <NUM> of the second sector-shaped plate <NUM>, the first mating feature <NUM> of the second sector-shaped plate <NUM> mates with the second mating feature <NUM> of the third sector-shaped plate <NUM>, and so forth. As such, each of the sector-shaped plates <NUM>-<NUM> overlaps in an axial direction with two adjacent ones of the sector-shaped plates <NUM>-<NUM>. For example, the first sector-shaped plate <NUM> overlaps in an axial direction with the second sector-shaped plate <NUM> and the fourth sector-shaped plate <NUM>. As used herein, an axial direction refers to a direction that is perpendicular to a diameter or radius of a disc-shaped plate.

This mating design prevents the sector-shaped plates <NUM>-<NUM> from being axially displaced or moved under high pressure of the fluid flow. For example, if a uniform force is applied across the first side <NUM> (e.g., an upstream facing side) or the second side <NUM> (e.g., a downstream facing side) of the disc-shaped plate <NUM>, the first and second mating features <NUM>, <NUM> of each of the sector-shaped plates <NUM>-<NUM> prevent the sector-shaped plates <NUM>-<NUM> from collapsing or being axially displaced. One force component is transmitted at contact surfaces of the first and second mating features <NUM>, <NUM> that are parallel to the first and second sides <NUM>, <NUM> of the disc-shaped plate <NUM>. This force is contained by a step or other parallel-surface feature where the disc-shaped plate <NUM> is mounted (e.g., by the shoulder <NUM> of the recess <NUM> shown in <FIG>). Another force component may be transmitted at oblique surfaces (e.g., the angled surfaces of the first and second mating features <NUM>, <NUM>) that converts into a radial separation force. This force component is contained by an inside diameter of a cavity where the disc-shaped plate <NUM> is mounted (e.g., by the inner dimeter surface <NUM> of the recess <NUM> shown in <FIG>). Thus, the example mating design can reduce or prevent bending without the need for support structures or fasteners. Therefore, in this example, the plurality of sector-shaped plates <NUM>-<NUM> are not coupled by fasteners or a support structure. In other examples, the first and second mating features <NUM>, <NUM> may be shaped differently. Various examples of other shaped mating features are disclosed herein. The amount of axial overlap can be sized according to pressure loading requirements.

In some examples, the mating design is resistant to movement if a uniform load is applied across the disc-shaped plate <NUM>, but the disc-shaped plate <NUM> may be weak and potentially collapse if a non-uniform force (e.g., a point force) is applied to a specific location on one of the sector-shaped plates <NUM>-<NUM>. For example, referring to <FIG>, if a point force is applied in the direction of the arrow near an edge of the third sector-shaped plate <NUM>, the point force may cause a torque on the third sector-shaped plate <NUM> that causes the third sector-shaped plate <NUM> to twist because there are no overlapping mating feature behind the third sector-shaped plate <NUM> near that edge. Other example mating feature designs are disclosed herein that have dual overlapping designs, such that a point force would not cause twisting or collapsing of the sector-shaped plates <NUM>-<NUM>.

In this example, the sector-shaped plates <NUM>-<NUM> include the openings <NUM> (flow paths) along the portions of the sector-shaped plates <NUM>-<NUM> forming the first and second mating features <NUM>, <NUM>. When the sector-shaped plates <NUM>-<NUM> are assembled in the disc-shaped plate <NUM>, the openings <NUM> in the portions of the sector-shaped plates <NUM>-<NUM> forming the first and second mating features <NUM>, <NUM> align with corresponding openings <NUM> in the first and second mating features <NUM>, <NUM> of the adjacent sector-shaped plates <NUM>-<NUM>. In some examples, this maximizes the number of flow paths through the disc-shaped plate <NUM>. In other examples, the sector-shaped plates <NUM>-<NUM> may not include openings along the portions of the sector-shaped plates <NUM>-<NUM> forming the first and/or second mating features <NUM>, <NUM>.

<FIG> is a perspective cross-sectional view of an example noise attenuator <NUM> in which the example disc-shaped plate <NUM> may be implemented. The noise attenuator <NUM> includes a body <NUM> defining a fluid passageway <NUM> between an inlet <NUM> and an outlet <NUM>. The body <NUM> has an inlet flange <NUM> at the inlet <NUM> to be coupled (e.g., via threaded fasteners) to an upstream device or pipe. For example, the inlet flange <NUM> may be coupled to the regulator outlet <NUM> of <FIG> and <FIG>. In other examples, the noise attenuator <NUM> may be coupled to and/or otherwise integrated with any other type of process control device (e.g., a valve) and/or any other device that changes a characteristic of a fluid and creates noise. The body <NUM> also has an outlet flange <NUM> at the outlet <NUM> to be coupled (e.g., via threaded fasteners) to an inlet flange <NUM> of a downstream pipe <NUM> shown in <FIG>.

In this example, the disc-shaped plate <NUM> is disposed in the fluid passageway <NUM> at or near the outlet <NUM>. As such, the example disc-shaped plate <NUM> may be referred to as an end plate. In the illustrated example, the body <NUM> includes a recess <NUM> formed in the outlet flange <NUM> around the outlet <NUM>. The recess <NUM> forms a shoulder <NUM> and an inner diameter surface <NUM>. The disc-shaped plate <NUM> is disposed in the recess <NUM> such that an outer peripheral region of the first side <NUM> of the disc-shaped plate is engaged with the shoulder <NUM>, and the outer peripheral edge <NUM> is engaged with or near the inner diameter surface <NUM>. An inlet <NUM> of the downstream pipe <NUM> has a smaller diameter than the disc-shaped plate <NUM>. As such, when the inlet flange <NUM> of the downstream pipe <NUM> is coupled to the outlet flange <NUM> of the noise attenuator <NUM>, a face <NUM> of the inlet flange <NUM> engages the second side <NUM> of the disc-shaped plate <NUM>. As a result, the outer peripheral region of the disc-shaped plate <NUM> is clamped between the outlet flange <NUM> of the body <NUM> and the inlet flange <NUM> of the downstream pipe <NUM>. This clamping prevents radial and axial displacement of the disc-shaped plate <NUM>. In some examples, the shoulder <NUM> and the face <NUM> are in direct contact with the disc-shaped plate <NUM>. In other examples, one or more spacers may be disposed between the shoulder <NUM> and the disc-shaped plate <NUM> and/or the face <NUM> and the disc-shaped plate <NUM>.

In the illustrated example, the recess <NUM> is the same thickness or depth as the disc-shaped plate <NUM>. This helps prevents leaking that could potentially occur between the sector-shaped plates <NUM>-<NUM> in the radial direction. Also, compared to known attenuators, this design also eliminates the need for an end plate o-ring to seal against the body <NUM>, and/or end plate bolts to be secured on the body <NUM>.

Further, as disclosed above, the mating features of the sector-shaped plates <NUM>-<NUM> (<FIG>) prevent the sector-shaped plates <NUM>-<NUM> from being axially displaced and/or otherwise collapsing under pressure by the flow of fluid across the disc-shaped plate <NUM>. The mating features may be designed to prevent axial separation in the upstream direction, the downstream direction, or both. Therefore, the example disc-shaped plate <NUM> does not require threaded fasteners or support structures (e.g., a central shaft, a support frame, etc.). In this example, the disc-shaped plate <NUM> is only supported by clamping of the outer peripheral region of the disc-shaped plate <NUM>. Eliminating the need for fasteners eliminates many drawbacks experienced with fasteners. For example, fasteners may need to be re-tightened as they become loose overtime. Fasteners also often require support structures. Further, fasteners create limited joint surfaces that carry high stresses. On the other hand, the example mating feature design provides larger, lower-stress joint surfaces. Further, assembly is easier without the fasteners, because the disc-shaped plate <NUM> can be easily inserted into the recess <NUM> before coupling the outlet flange <NUM> of the body <NUM> to the inlet flange <NUM> of the downstream pipe <NUM>. This reduces costs associated with assembling the noise attenuator <NUM>. Further, because the disc-shaped plate <NUM> is sized to fit a specific recess, the disc-shaped plate <NUM> can be made as thick as structurally required, thereby eliminating the need for adjacent support structures.

In other examples, the sector-shaped plate <NUM>-<NUM> may be coupled or supported by fasteners or a support structure, such as in the case of remote assembly or temporary shelf storage (outside of the body <NUM>). In some examples, the plate-to-plate interfaces may be reinforced with glue, a bonding element, fasteners, or an outer holding ring.

In the illustrated example, the noise attenuator <NUM> includes additional plates <NUM>, <NUM> (sometimes referred to as internal plates) disposed in the fluid passageway <NUM> upstream of the disc-shaped plate <NUM>. In the illustrated example, the plates <NUM>, <NUM> are coupled via a plurality of rods <NUM> (one of which is referenced in <FIG>) that prevent or reduce bending of the plates <NUM>, <NUM>. The plates <NUM>, <NUM> include openings defining flow paths through the respective plates <NUM>, <NUM> to attenuate noise. The plates <NUM>, <NUM> incrementally slow and reduce noise of the flow fluid. In this example, the rods <NUM> are not coupled to the disc-shaped plate <NUM>. Thus, in this example, the disc-shaped plate <NUM> (e.g., the end plate) is not coupled to the plates <NUM>, <NUM> (e.g., the internal plates). In other examples, the rods <NUM> may extend to and be coupled to the disc-shaped plate <NUM>. Additionally or alternatively, in some examples, one or more spacers may be disposed between each of the plates <NUM>, <NUM> and/or between the plate <NUM> and the disc-shaped plate <NUM>. For example, <FIG> shows an example spacer <NUM> disposed between the plate <NUM> and the disc-shaped plate <NUM>. As such, upstream pressured loads from the plates <NUM>, <NUM> are transferred to the disc-shaped plate <NUM> via the spacer <NUM>. In other examples, more spacers may be used. In other examples, spacers may not be disposed between the plate <NUM> and the disc-shaped plate <NUM>. In other examples, more or fewer plates may be implemented. In this example, each of the plates <NUM>-<NUM> is a single piece perforated metal plate. However, in other examples, one or more of the plates <NUM>-<NUM> may be the same as the disc-shaped plate <NUM>. Thus, multiple ones of the disc-shaped plate <NUM> may be implemented. Separation distance between the plates can be achieved by axial spacers, bore steps, nuts, etc. In other examples, the noise attenuator <NUM> may not include any internal plates, such that the disc-shaped plate <NUM> may be the only plate implemented in the noise attenuator <NUM>.

<FIG> are perspective views of the first sector-shaped plate <NUM>. The first sector-shaped plate <NUM> has the first radial edge <NUM> forming the first mating feature <NUM> and the second radial edge <NUM> forming the second mating feature <NUM>. As disclosed above, in some examples, the first sector-shaped plate <NUM> is constructed by a 3D printer, such as the 3D printer <NUM> of <FIG>. In some examples, the first sector-shaped plate <NUM> is printed in a vertical orientation, starting with the radial second edge <NUM>, as shown by the direction of the arrows in <FIG>. This enables multiple sectors-shaped plates to be printed side-by-side during the same print batch, similar to the arrangement shown in <FIG>. In some examples, this results in the openings <NUM> being tear-dropped shaped, similar to the opening <NUM> shown in <FIG>. In other examples, the openings <NUM> may be shaped differently. In other examples, the first sector-shaped plate <NUM> may be printed in a different orientation (e.g., horizontal).

In some examples, the flow paths formed by the openings <NUM> are not uniformly shaped, but may have variable areas and section profiles between the upstream face (e.g., the first side <NUM> (<FIG>)) and the downstream face (e.g., the second side <NUM> (<FIG>)) of the disc-shaped plate <NUM>. For example, in acoustic applications, one or more of the openings <NUM> may have two or more expansion stages, which improves noise reduction. In another example, where only one expansion stage is implemented, a first portion (e.g., <NUM>%) of a flow path may be formed by a larger hole, followed by a smaller hole at the downstream face.

<FIG> is a perspective view another example sector-shaped plate <NUM> that may be used to form a disc-shaped plate for a noise attenuator, similar to the sector-shaped plates <NUM>-<NUM> disclosed above. Multiple ones of the sector-shaped plate <NUM> may be constructed and arranged together to form a disc-shaped plate. In particular, in this example, four of the sector-shaped plates <NUM> may be arranged together to form a disc-shaped plate, an example of which is shown in <FIG>. The resulting disc-shaped plate may be disposed in a fluid passageway similar to the disc-shaped plate <NUM> shown in <FIG>. The sector-shaped plate <NUM> may be printed via a 3D printer, such as the printer <NUM> of <FIG>.

In the illustrated example, the sector-shaped plate <NUM> has a first radial edge <NUM> forming a first mating feature <NUM> and a second radial edge <NUM> forming a second mating feature <NUM> that is complementary to the first mating feature <NUM>. In this example, the first mating feature <NUM> is a v-shaped wedge, and the second mating feature <NUM> is a v-shaped groove. When four of the sector-shaped plates <NUM> are assembled into a disc-shaped plate, the first mating feature <NUM> of each of the sector-shaped plates <NUM> engages or mates with the second mating feature <NUM> of an adjacent one of the sector-shaped plates <NUM>. As such, each of the sector-shaped plates <NUM> overlaps in an axial direction with two adjacent ones of the sector-shaped plates <NUM>. This mating design prevents the sector-shaped plates <NUM> from being axially displaced or moved under high pressure of the fluid flow.

In the illustrated example, the sector-shaped plate <NUM> has a first wall <NUM> forming a first side of the sector-shaped plate <NUM> and a second wall <NUM> forming a second side of the sector-shaped plate <NUM>. The sector-shaped plate <NUM> has a first plurality of openings <NUM> (one of which is reference in <FIG>) extending between the first and second walls <NUM>, <NUM>. The openings <NUM> form flow paths through the sector-shaped plate <NUM> to attenuate noise.

In some examples, the sector-shaped plate <NUM> is substantially solid, and the openings <NUM> extend through the body of the sector-shaped plate <NUM>. For example, <FIG> shows an example of the sector-shaped plate <NUM> that been cross-sectioned along a center plane of the sector-shaped plate <NUM>. In this example, the internal body of the sector-shaped plate <NUM> is substantially solid and the openings <NUM> (one of which is referenced in <FIG>) extend through the solid body.

In other examples, the internal body of the sector-shaped plate <NUM> may be partially hollow or include another structure, such as a lattice structure. For example, <FIG> shows another cross-sectioned version of the sector-shaped plate <NUM>. In this example, the inside of the sector-shaped plate <NUM> has an internal lattice structure <NUM>. The internal lattice structure <NUM> forms a plurality of openings <NUM> (one of which is referenced in <FIG>). In this example, the openings <NUM> are diamond shaped. In some examples, this diamond shaped lattice structure allows for easier printing in the vertical direction by limiting wall overhang. In other examples, the internal lattice structure <NUM> may form differently shaped openings (e.g., squares, triangles, hexagons, octagons, etc.). <FIG> is a top view of the sector-shaped plate <NUM> of <FIG> showing the internal lattice structure <NUM> and the openings <NUM>. The openings <NUM> fluidly connect the openings in the first and second walls <NUM>, <NUM> (<FIG>). In the illustrated example, the openings <NUM> of the internal lattice structure <NUM> are larger than the openings in the first and second walls <NUM>, <NUM>. Therefore, each of the openings <NUM> of the internal lattice structure <NUM> fluidly connects multiple ones of the openings in the first and second walls <NUM>, <NUM>.

<FIG> is a side cross-sectional view of the sector-shaped plate <NUM> showing one of the openings <NUM> of the internal lattice structure <NUM>. The first wall <NUM> has a first plurality of openings <NUM> (three of which are referenced in <FIG>) and the second wall <NUM> has a second plurality of openings <NUM> (three of which are referenced in <FIG>). The opening <NUM> of the internal lattice structure <NUM> fluidly connects a set of the first plurality of openings <NUM> and a set of the second plurality of openings <NUM>. In some examples, the internal lattice structure <NUM> is formed through the entire sector-shaped plate <NUM>, including the portions forming the first and second mating features <NUM>, <NUM>. In other examples, the internal lattice structure <NUM> is only formed in the center or main portion of the sector-shaped plate <NUM>, whereas the portions forming the first and second mating features <NUM>, <NUM> do not include an internal lattice structure.

The example internal lattice structure <NUM> reduces the amount of material used to build the sector-shaped plate <NUM>. In other words, the sector-shaped plate <NUM> contains less material than a sector-shaped plate having a solid internal structure. As such, the sector-shaped plate <NUM> is less expensive to manufacture and results in a lighter disc-shaped plate. As disclosed above, the sector-shaped plate <NUM> can be constructed by a 3D printer. The internal lattice structure <NUM> can be formed during the 3D printing process. Such an internal lattice structure may not be feasible via a traditional (subtractive) machining process.

Further, with this design, the first and second walls <NUM>, <NUM> effectively form two attenuator plates. For example, the first wall <NUM> has the first plurality of openings <NUM> and the second wall <NUM> has the second plurality of openings <NUM>. Thus, this design results in two flow stages (dual expansion), which further improves the noise attenuating performance of the sector-shaped plate <NUM>. The first and second walls <NUM>, <NUM> can be thinner or thicker depending on the structural loading demands.

In some examples, instead of having an internal lattice structure, the internal section of the sector-shaped plate may be completely hollow. In some examples, one or more portions of a disc-shaped plate may include a hollow section or a lattice structure, while one or more other portions may be solid. In another example, the entire sector-shaped plate may be a lattice structure, and no side walls are used. In such an example, the flow paths have constant cross-sections across the plate thickness, defined by the lattice geometry. It is understood that any of the example disc-shaped plates and/or individual sector-shaped plates disclosed herein may include an internal lattice structure or variations thereof as disclosed in connection with this example.

<FIG> is a perspective view of an example disc-shaped plate <NUM> formed by the sector-shaped plate <NUM> (also referred to herein as the first sector-shaped plate <NUM>) and three other sector-shaped plates <NUM>-<NUM> (referred to as the second, third, and fourth sector-shaped plates <NUM>-<NUM>). The second, third, and fourth sector-shaped plates are the same (i.e., have the same size and shape) as the first disc-shaped plate <NUM>, and may also be printed via a 3D printer, such as the 3D printer <NUM> of <FIG>. The disc-shaped plate <NUM> may be disposed in a fluid passageway similar to the disc-shaped plate <NUM> shown in <FIG>.

When the sector-shaped plates <NUM>, <NUM>-<NUM> are assembled into the disc-shaped plate <NUM>, the first mating feature <NUM> (<FIG>) of each of the sector-shaped plates <NUM>, <NUM>-<NUM> engages or mates with the second mating feature <NUM> (<FIG>) of an adjacent one of the sector-shaped plates <NUM>, <NUM>-<NUM>. As such, each of the sector-shaped plates <NUM>, <NUM>-<NUM> overlaps in an axial direction with two adjacent ones of the sector-shaped plates <NUM>, <NUM>-<NUM>. This mating design prevents the sector-shaped plates <NUM>-<NUM> from being axially displaced or moved under high pressure of the fluid flow from the upstream or downstream directions. Because of the v-shaped overlap, an isolated point force would not cause one of the sector-shaped plates <NUM>, <NUM>-<NUM> to rotate or twist in this example. The intra-locking design of the mating features <NUM>, <NUM> (<FIG>) prevents twisting in both directions (radially outward moment, and radially inward moment), thereby preventing collapse between the sector-shaped plates <NUM>, <NUM>-<NUM>.

<FIG> show an example sequence of assembling the sector-shaped plates <NUM>, <NUM>-<NUM> into the disc-shaped plate <NUM> (<FIG>). The sector-shaped plates <NUM>, <NUM>-<NUM> may be laid on a flat surface radially spread apart. Then, the sector-shaped plates <NUM>, <NUM>-<NUM> may be pushed radially inward until all of the sector-shaped plates <NUM>, <NUM>-<NUM> mate.

In some examples, each of the sector-shaped plates <NUM>, <NUM>-<NUM> may include an internal lattice structure, as disclosed in connection with <FIG>. In other examples, the sector-shaped plates <NUM>, <NUM>-<NUM> may not include an internal lattice structure. Instead, the openings may extend straight through the respective sector-shaped plates <NUM>, <NUM>-<NUM>, as disclosed in connection with <FIG>. For example, <FIG> shows a cross-sectional view of the example disc-shaped plate <NUM> in which the disc-shaped plate <NUM> does not include an internal lattice structure. Instead, the openings <NUM> extend through the solid internal structure of the disc-shaped plate <NUM>.

In some examples, the openings <NUM> are omitted from one or more sections of the sector-shaped plates <NUM>, <NUM>-<NUM> near the interfaces of the first and second mating features <NUM>, <NUM> (<FIG>). In some examples, this interface is relatively thin. For example, as shown in <FIG>, a first section <NUM> along the second radial edge <NUM> of the first sector-shaped plate <NUM> does not include openings. Also, a second section <NUM> does not include openings. The second section <NUM> corresponds to the radial edge forming the first mating feature of the second sector-shaped plate <NUM>. In other examples, one or more of these sections may still have openings.

For example, <FIG> is a perspective view of another example disc-shaped plate <NUM>. The disc-shaped plate <NUM> is substantially the same as the disc-shaped plate <NUM> disclosed above. However, in this example, the disc-shaped plate <NUM> does not include the section <NUM> of omitted openings. <FIG> shows the disc-shaped plate <NUM> with the first wall removed.

<FIG> illustrate example disc-shaped plates having various shaped mating features. The mating features function substantially the same as the examples disclosed above to prevent or reduce axial displacement of the sector-shaped plates. In some examples, the mating features not only overlap in the axial direction, but also overlap in the circumferential direction. Therefore, engagement may occur in specific directions.

The openings through the respective disc-shaped plates are not shown in <FIG>. However, it is understood that the disc-shaped plates of <FIG> may include a plurality of openings extending through the respective disc-shaped plates. Any of the disc-shaped plates of <FIG> may include internal lattice structure, similar to the internal lattice structure in the examples disclosed above. Each of the disc-shaped plates is formed by a plurality of sector-shaped plates. Any number of sector-shaped plates may be utilized. The sector-shaped plates may be printed in a 3D printer, such as the 3D printer <NUM> of <FIG>. Some of the disc-shaped plates of <FIG> are more suitable for machining operations because of complex printing. Any of the disc-shaped plates of <FIG> may be disposed in a fluid passageway similar to the disc-shaped plate <NUM> shown in <FIG>.

In some of the examples, such as in <FIG>, the sector-shaped plates overlap in the axial direction with two other ones of the sector-shaped plates at the mating features. In other examples, the sector-shaped plates may be designed such that the sector-shaped plates overlap in the axial direction with more than two other ones of the other sector-shaped plates at the mating features. In some examples, such as in <FIG> and <FIG>, a disc-shaped plate may have a groove or opening in the center. This groove or opening may be used to receive a support member, such a central rod. In some examples, a disc-shaped plate may include additional openings to receive other support rods for supporting the disc-shaped plate. A disc-shaped plate may have regions that are fully solid or with thicker walls if supporting rods or spacers are utilized.

<FIG> is a flowchart representative of an example method <NUM> of manufacturing a disc-shaped plate and installing the disc-shaped plate in a fluid body. The example method <NUM> is described in connection with the disc-shaped plate <NUM> of <FIG>. However, it is understood that the example method <NUM> may be similarly performed in connection with any of the example disc-shaped plates disclosed herein.

At block <NUM>, the example method <NUM> includes printing, via a 3D printer, a plurality of sector-shaped plates. For example, the sector-shaped plates <NUM>-<NUM> may be printed via a 3D printer, such as the 3D printer <NUM> of <FIG>. In some examples, each of the sector-shaped plates <NUM>-<NUM> is printed in a vertical orientation. This enables multiple sector-shaped plates to be printed side-by-side in the same print batch. The sector-shaped plate <NUM>-<NUM> may be printed simultaneously as part of the same print batch or at different times. In some examples, one or more post-machining operations (e.g., drilling, cutting, sanding, etc.) may be performed to smooth the surfaces of the sector-shaped plates <NUM>-<NUM>. Each of the sector-shaped plates <NUM>-<NUM> includes the first mating feature <NUM> and the second mating feature <NUM> that is complementary to the first mating feature <NUM>. The sector-shaped plates <NUM>-<NUM> include the openings <NUM>. In some examples, the sector-shaped plates <NUM>-<NUM> may include an internal lattice structure.

At block <NUM>, the example method <NUM> includes assembling the sector-shaped plates into a disc-shaped plate. For example, the sector-shaped plates <NUM>-<NUM> may be laid on a flat surface, radially spaced apart, and then moved radially inward toward each ohter. The mating features engage or mate with corresponding mating features of the adjacent sector-shaped plates <NUM>-<NUM>.

At block <NUM>, the example method <NUM> includes 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. For example, as shown in <FIG>, the disc-shaped plate <NUM> is disposed in the fluid passageway <NUM> of the body <NUM> of the noise attenuator <NUM>. In some examples, the disc-shaped plate <NUM> is coupled to the body <NUM> by clamping the outer peripheral region of the disc-shaped plate <NUM> between the body <NUM> and the downstream pipe <NUM>. This clamping locks the outer peripheral region of the disc-shaped plate <NUM> in place. Further, the mating design prevents or reduces axial displacement of the sector-shaped plates <NUM>-<NUM>. As such, in some examples, the method <NUM> does not include using threaded fasteners or support structures to construct the disc-shaped plate <NUM> or couple the disc-shaped plate <NUM> to the body <NUM>. However, in other examples, fasteners or support structures may be used.

While in many of the examples disclosed herein a disc-shaped plate is coupled to or otherwise integrated with a body of a noise attenuator, any of the example plates and/or plate assemblies disclosed herein can instead be coupled to or integrated directly into a body of the process control device creating the audible noise. For example, a disc-shaped plate may be coupled to an outlet of a regulator or a valve to attenuate noise as the fluid exits the regulator or a valve.

Any of the example plates and/or plate assemblies disclosed herein can also be implemented in other devices using multi-path flow plates, such as flame arrestors. In flame arrestor applications, the flow paths can be sized with a specific Maximum Experimental Safe Gap (MESG) or hole diameter based on the process gas. In some examples, identical plates can be stacked depending on the operation parameters. In some examples, plates with identical cross-sections can be 3D printed taller or shallower depending on the application and/or media.

The example interlocking plate designs disclosed herein can also be used in other applications not related to controlling fluid flow across a plate. For example, many valves and other flow control devices have a top section with an opening that is sealed with a lid plate. If the valve requires servicing, for instance, the lid plate can be removed to access the internal section of the valve. The lid plate is typically a large plate with a flange that extends beyond the dimensions of the opening, such that the flange can be bolted to a corresponding flange on the valve body or a cap that covers the lid plate. Instead, an example disc-shaped plate formed by a plurality of sector-shaped plates with mating features can be used. In such an example, the sector-shaped plates would not have flow path openings, but instead may be completely solid. For example, an inner diameter of the opening in the valve body may have a recess, similar to the recess <NUM> shown in the outlet <NUM> of the body <NUM> in <FIG>, and the plurality of sector-shaped plates may be arranged into a disc-shaped plate and inserted into the recess. Then, a retainer ring or cross plate may be used to clamp or secure the outer peripheral region of the disc-shaped plate to the valve body. As such, the disc-shaped plate could be used as a lid to cap or seal off the opening. Such a disc-shaped plate with a plurality of sector-shaped plates may be easier to install and remove than the traditional lid plate. Further, this would enable larger plates to be constructed via 3D printing, which is advantageous because it can be used to create complex features in the sector-shaped plates.

While in many of the examples disclosed herein a disc-shaped plate is formed by a plurality of sector-shaped plates, in other examples, that do not form part of the present invention, any of the example disc-shaped plates may be formed by one or more plate sections that are not sector-shaped. For example, a disc-shaped plate may be formed by a plurality of strips that, when arranged next to each other, form the disc-shaped plate. In another example, a disc-shaped plate may be formed by a center piece surrounded by radial sections.

Claim 1:
A disc-shaped plate (<NUM>) for a noise attenuator (<NUM>), the disc-shaped plate (<NUM>) comprising:
a plurality of sector-shaped plates (<NUM>, <NUM>, <NUM>, <NUM>), the plurality of sector-shaped plates (<NUM>, <NUM>, <NUM>, <NUM>) having openings (<NUM>) defining flow paths, each of the plurality of sector-shaped plates (<NUM>, <NUM>, <NUM>, <NUM>) having a first radial edge (<NUM>) forming a first mating feature (<NUM>) and a second radial edge (<NUM>) forming a second mating feature (<NUM>) that is complementary to the first mating feature (<NUM>) such that, with the plurality of sector-shaped plates (<NUM>, <NUM>, <NUM>, <NUM>) arranged together, the first mating feature (<NUM>) of each of the plurality of sector-shaped plates (<NUM>, <NUM>, <NUM>, <NUM>) mates with the second mating feature (<NUM>) of an adjacent one of the plurality of sector-shaped plates (<NUM>, <NUM>, <NUM>, <NUM>), and, with the plurality of sector-shaped plates (<NUM>, <NUM>, <NUM>, <NUM>) arranged together, a portion of each of the plurality of sector-shaped plates (<NUM>, <NUM>, <NUM>, <NUM>) overlaps in an axial direction with an adjacent one of the plurality of sector-shaped plates (<NUM>, <NUM>, <NUM>, <NUM>).