CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority pursuant to relevant sections of 35 U.S.C. § 119 to U.S. Provisional Application Serial No. 61/699,153, filed on September 10, 2012 and entitled "NOISE ATTENUATION DEVICE AND APPARATUS COMPRISED THEREOF," the content of which is herein incorporated by reference in its entirety.

BACKGROUND

[0002] The subject matter of this disclosure relates to noise attenuation in fluid couplings, e.g., valves and flow regulators.

[0003] The flow of working fluids (e.g., gas and liquids) through fluid couplings can generate unfavorable operating conditions. Changes in pressure of the working fluid across the fluid coupling can lead to fluid dynamics that cause noise, heat, and mechanical vibrations. The resulting noise may reach well above 100 dba and, often, exceed regulations that set limits on acceptable exposure to noise in the workplace.

[0004] Some fluid couplings incorporate devices that can address these problems. These devices direct the working fluid through channels that form a tortuous pathway with multiple turns. The channels damp noise levels, e.g., by gradually changing potential energy in the working fluid to kinetic energy. However, in many fluid couplings, a throttling element (e.g., a diaphragm) is found in close proximity to the channels. This configuration of the throttling element can reduce the efficacy of the attenuating device because the throttling element may prevent the working fluid from flowing through some of the channels of the attenuating device.

[0005] Failure to utilize all of the available channels can also reduce the lifetime of these devices. Often, the channels operate under maximum flow conditions (e.g., maximum velocity) at all times because the present configurations of the throttling element exposes only a limited number of the channels depending on the volume and/or other flow conditions. Accordingly, these flow conditions can hasten wear, erosion, and other damage that occurs, in particular, to those channels that receive fluid flow when the throttling element is both partially and fully open.

BRIEF DESCRIPTION OF THE INVENTION

[0006] This disclosure describes improvements in noise attenuation for fluid couplings that address, among other things, wear issues in a cost-effective design. As set forth below, these improvements separate the noise attenuation device from the throttling element. The resulting gap and/or spacing allows a working fluid (e.g., gas and liquids) to flow through all of the channels at all positions of the throttling element. Further, the position of the noise attenuation device relative to the throttling element distributes the flow evenly across the channels, thereby managing fluid velocity in each channel to levels that reduce wear and erosion damage.

[0007] Construction of embodiments of the noise attenuation device utilize multiple plates with openings that, when arranged together, form the structure of the channels. The channels comprise a plurality of turns, which change the direction of the flow to reduce noise. However, these devices employ plates that simplify assembly of the channels. In one embodiment, the noise attenuation device requires only two types of plates. Each type of plate features a different pattern of openings. Moreover, based on the geometry and layout of the openings, embodiments of the noise attenuation device can include a stacked configuration that positions the plates in only two orientations to form the channels. This features helps avoid improper orientation that would fail to properly form channels through which the working fluid can flow.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Reference is now made briefly to the accompanying drawings, in which:

[0009] FIG. 1 depicts a perspective view of an exemplary embodiment of a noise attenuation device for use in connection with a fluid coupling; [0010] FIG. 2 depicts a cross-section of the noise attenuation device of FIG. 1;

[0011] FIG. 3 depicts the noise attenuation device of FIG. 1 in exploded form;

[0012] FIG. 4 depicts a detail view of the noise attenuation device of FIG. 3;

[0013] FIG. 5 depicts a perspective view of an example of a plate for use in a noise attenuation device;

[0014] FIG. 6 depicts a perspective view of an example of a plate for use in a noise attenuation device;

[0015] FIG. 7 depicts a perspective view of an example of a plate for use in a noise attenuation device;

[0016] FIG. 8 depicts a perspective view of an example of a housing for use in a noise attenuation device;

[0017] FIG. 9 depicts a top view of the housing of FIG. 8;

[0018] FIG. 10 depicts a top view of an example of a housing for use in a noise attenuation device;

[0019] FIG. 11 depicts an example of a fluid coupling that incorporates an example of a noise attenuation device;

[0020] FIG. 12 depicts the fluid coupling of FIG. 10 in exploded form;

[0021] FIG. 13 depicts a cross-section view of the fluid coupling of FIG. 10; and

[0022] FIG. 14 depicts a cross-section of a fluid coupling that incorporates an example of a noise attenuation device. [0023] Where applicable like reference characters designate identical or corresponding components and units throughout the several views, which are not to scale unless otherwise indicated.

DETAILED DISCUSSION OF THE INVENTION

[0024] FIGS. 1, 2, 3, and 4 illustrate an exemplary embodiment of a noise attenuation device 100 (also "device 100") that can reduce noise that occurs in fluid couplings (e.g., valves and flow regulators). In FIG. 1, the device 100 has an upstream side 102 and a downstream side 104, the orientation of which depends on the direction of flow F of a working fluid. The device 100 includes a housing 106 that forms a central opening 108 with one or more apertures (e.g., a first aperture 110 and a second aperture 112) found therein. Examples of the housing 106 can comprise carbon steel and like materials suitable for transport of fluids, e.g., natural gas. The housing 106 can fit into existing flow couplings, thereby permitting the noise attenuation device 100 much flexibility for retrofit into existing couplings and related devices.

[0025] As best shown in FIG. 2, which is a cross-section of the first aperture 110 taken at line 2-2 in FIG. 1, the device 100 also includes a plate assembly 114 disposed, in this example, in the first aperture 110. The plate assembly 114 features a stacked plate assembly to form one or more channels 118. Each of the channels 118 have projections 119 that change the direction of flow F. These changes in flow direction reduce the energy (e.g., kinetic energy) of the flow F across the device 100. In one example the turns change the direction by about 90°, although this disclosure contemplates configurations of the plate assembly 114 with shallower and or wider turns and combinations thereof.

[0026] The exploded assembly of FIG. 3 provides more details of the plate assembly 114. In one embodiment, the plate assembly 114 includes a first plate 120 with openings in a first pattern 122 and a second plate 124 with openings in a second pattern 126 that is different from the first pattern 122. The plate assembly 114 utilizes an alternating configuration where the first plates 120 are adjacent the second plate 124 throughout the plate assembly 114. This configuration orients the first pattern 122 and the second pattern 126 relative to one another. When in the appropriate orientation, the openings of the first plate 120 and the openings in the second plate 124 form the channels (e.g., channels 118 of FIG. 2) that dissipate energy of the flow F as the working fluid transits through the device 100. The placement and orientation of the second plates 124 in the alternating configuration is determined by the position of the second plates 124, e.g., whether on the upstream side 102 and the downstream side 104 of the first plate 120 in the plate assembly 114.

[0027] FIG. 4 illustrates a detail view of the plate assembly 114 to further describe the placement and orientation of the second plates 124 in the plate assembly 114. As shown in FIG. 4, the plate assembly 114 includes the first plate 120 and a pair of the second plates (e.g., an upstream plate 128 and a downstream plate 130). The second plates 128, 130 have a first side 132 and a second side 134. In the present configuration, on the upstream side 102, the second side 134 of the upstream plate 128 resides proximate the first plate 120. On the downstream side 104, the proposed configuration positions the first side 132 of the downstream plate 130 proximate the second plate 120.

[0028] The orientation of the upstream plate 128 and the downstream plate 130 exploits the distribution of openings in the second pattern 126 to properly form the channels with the openings in the first pattern 122. To this end, the plate assembly 114 requires only two different styles and/or types of patterns of openings. This feature simplifies construction, i.e., the end user need only identify the appropriate orientation of the second plates 128, 130 in the plate assembly 114. This orientation can be identified by presenting markings (e.g., etchings, colors, symbols, etc.) on the sides of the second plates 128, 130 to clearly demarcate and differentiate the first side 132 from the second side 134. Moreover, for purposes of manufacturing, the proposed configuration of the first plate 120 and the second plates 128, 130 requires production tooling and/or other manufacturing and assembly implements that need only generate two styles of plates (e.g., the first plate 120 and the second plate 128, 130). This requirement can reduce tooling costs and other expenses related to manufacture of the plate assembly 114 and/or the noise attenuation device 100 in general.

[0029] Focusing next on the plates (e.g., first plate 120 and second plates 128, 130), FIG. 5 depicts a schematic diagram of an example of a plate 200 that can be used as a material blank for construction of the plates found in the plate assembly 114 of FIGS. 2, 3, and 4). The plate 200 has a plate body 202 with a centerline 204 and fastening features (e.g., a first fastener opening 206 and a second fastener opening 208). The fastening features 206, 208 reside at a fastening area (e.g., a first fastening area 210 and a second fastening area 212). The fastening areas 210, 212 incorporates material of the plate body 202 about the fastening features 206, 208. The plate body 202 has an outer peripheral edge 214 that forms an elongated planar surface 216 with a first end 218 and a second end 220. The outer peripheral edge 214 can also form a curvilinear surface 222, which may extend between the first end 218 and the second end 220 of the elongated planar surface 214. In one example, the plate body 202 may include one or more orientation features, in the form of one or more planar surfaces (e.g., a first planar surface 224, a second planar surface 226, and a third planar surface 228) disposed about the curvilinear surface 222.

[0030] Stacking multiple plates in the plate assembly 114 (FIGS. 2, 3, and 4) aligns the fastening features 206, 208. This configuration aligns the first fastener opening 206 and the second fastener opening 208 to create a pair of elongated holes that penetrates through the plate assembly 1 14. The elongated holes can receive fasteners (e.g., bolts and/or screw) that extend through the plate assembly 114 and secure, e.g., to the housing 106 (FIGS. 1 and 3). As an added benefit, the configuration also aligns the first fastening area 210 and the second fastening area 212. Such alignment creates elongated columns, which comprise the material incorporated in the first fastening area 210 and the second fastening area 212 on the plates in the plate assembly. These elongated columns provide strength and structural integrity to the plate assembly 114 to withstand the pressure, and other forces, that act upon the plate assembly 114 as the flow F travels through the channels 118 (FIG. 2).

[0031] FIG. 6 depicts an example of a first plate 300 that can be formed from the material blank of plate 200 (FIG. 5). Examples of the first plate 300 find use as the first plate 120 discussed above and shown in FIGS. 2, 3, and 4. In the present example of FIG. 6, the plate body 302 includes a centerline 304, fastening features 306, 308, and fastening areas 310, 312. The plate body 302 also includes a plurality of openings, generally identified as peripheral openings 330 and main openings 332. The latter, i.e., the main openings 332, are distributed across a majority of the surface of the plate body 302. The main openings 332 exhibit uniformly the same physical characteristics, e.g., shape and dimensions, which can be quantified in terms of a first side 334 and a second side 336. On the other hand, the peripheral openings 330 may have physical characteristics that are different from the main openings 332. Collectively, the peripheral openings 330 and the main openings 332 are part of a first pattern 338 (e.g., first pattern 122 of FIGS. 3 and 4).

[0032] As shown in the example of FIG. 6, the openings 330, 332 of the first pattern 338 are arranged in the same manner, or mirror image, on both sides of the centerline 304. This arrangement permits the first plate 300 to install in the plate assembly 114 (FIGS. 2, 3, and 4) independent of orientation, i.e., wherein the position of the first side 334 and/or the second side 336 proximate other plates defines the orientation in the plates assembly 114 (FIGS. 2, 3, and 4). Examples of the openings 330, 332 can have form factors that include square and rectangular shapes (shown in FIG. 6), although the openings 330, 332 in other examples of the first plate 300 may take other form factors (e.g., hexagonal, octagonal, etc.) that comport with the formation of channels as contemplated herein. For the main openings 332, the dimensions of the first side 334 and the second side 336 may define the form factor. For example, the first side 334 and the second side 336 may exhibit dimension that are the same (e.g., for square form factors) or different (e.g., for rectangular form factors). [0033] FIG. 7 depicts an example of a second plate 400 for use as the second plates 128, 130 (FIGS. 2, 3, and 4). In FIG. 7, the plate body 402 includes a centerline 404, fastening features 406, 408, and fastening areas 410, 412. The openings 430, 432 in the plate body 402 are part of a second pattern 440 (e.g., second pattern 126 in FIGS. 2, 3, and 4) that incorporates main openings 430 in different sets (e.g., a first set 442 and a second set 444). The orientation of the main openings 432 that populate the different sets 442, 444 can distinguish the first set 442 from the second set 444. For example, as shown in FIG. 7, the first side 434 of the main openings 432 in the first set 442 is generally longer than the second side 436 and, in one example, the shorter side is parallel to the elongated planar surface 416. In the second set 444, the second side 436 of the main openings 432 is shorter than the second side 436 and, in one example, the longer side is parallel to the elongated planar surface 416.

[0034] Moreover, the differences in the distribution of openings 430, 432 of the second plate 400 in its present form does not offer the symmetry (or mirror image) about the centerline 404 discussed in connection with the first plate 300 (FIG. 6) above. This lack of symmetry, however, affords the second plate 400 with variable orientations in the plate assembly 114 (FIGS. 1, 2, and 3). To this end, the configuration of openings 430, 432 in the second pattern 440 comports with the formation of channels when the second plate 400 is installed (either as the upstream plate 128 (FIG. 3) or the downstream plate 130 (FIG. 4)) in the plate assembly 114 (FIGS. 2, 3, and 4).

[0035] FIGS. 8 and 9 depict an example of a housing 500 for use as the housing 106 of FIGS. 1 and 3. The housing 500 includes a first attenuated opening 502 that is sized and configured to receive the plate assembly 114 (FIGS. 2, 3, and 4) therein. The housing 500 also includes a secondary opening 504 and a bore 506 which forms one or more surfaces 508 that can provide mating surfaces, e.g.., for seals and seal elements as contemplated herein. As shown in FIG. 9, which is a top view of the housing 500, the first attenuated opening 502 can comprise a support structure, e.g., in the form of a first support rib 510 and a second support rib 512. The support structures 510, 512 include a support and fastening element 514, which both supports the plate assembly 114 (FIGS. 1, 2, and 3) and provides, in one example, a threaded opening 516 to receive a fastener that penetrates the plate assembly. For example, the support and fastening element 514 is configured to support the elongated columns that form when plates of the above configurations are stacked together. Examples of the support and fastening element 514 can include a base structure that matches one or both of the fastening areas (e.g., the first fastening area 210 and the second fastening area 212 of FIG. 5). Moreover, the shape of the first attenuated opening 502 can mimic the outer peripheral edge of the plates, including the position and configuration of the orientation features. This shape can help to align the openings in the plates as the plates are stacked into the housing 500, e.g., during assembly of the plate assembly 114 (FIGS. 2, 3, and 4).

[0036] FIG. 10 depicts another example of a housing 600 that can accommodate a pair of plate assemblies. The housing 600 includes a first attenuated opening 602 and a second attenuated opening 618 that includes a support structure of the same construction as the first attenuated opening 602 (e.g., a first support rib 610 and a second support rib 612, each configured with a support and fastening element 614 and a threaded opening 616).

[0037] FIGS. 11, 12, and 13 depicts another exemplary embodiment of a noise attenuation device 700 that is part of a fluid coupling 702, e.g., in the form of a valve and/or a flow regulator. The fluid coupling 702 includes a fluid housing 704 with inlet/outlets (e.g., a first inlet/outlet 706 and a second inlet/outlet 708) that permit fluid (e.g., gas and liquid) to flow through the fluid housing 704. The fluid coupling 702 also includes a cover 710 that is disposed on the noise attenuation device 700.

[0038] FIG. 12 shows the fluid coupling 702 in partially exploded form. In the example of FIG. 12, the fluid coupling 702 further includes a diaphragm 712 and a throttling element 714. The noise attenuation device 700 includes a plate assembly 714 in position to receive flow of working fluid that exits the throttling element 714. As best shown in FIG. 13, which is a cross-section of the fluid apparatus 702 of FIG. 10 taken at line 13-13, the throttling element 714 is spaced apart from the plate assembly 716 by a gap 718.

[0039] During operation, the diaphragm 712 will open and close, thereby sealing portions of the throttling element 714 to prevent the flow or working fluid to the plate assembly 716. The gap 718 allows the working fluid access to all of the channels of the plate assembly 716 independent of the position of the diaphragm 712 on the throttling element 714. As discussed above, by providing full access to the channels, the gap 718 allows the working fluid to distribute evenly through the plate assembly 716. This even distribution prevents maximum flow to occur, which reduces wear and damage on the channels of the plate assembly.

[0040] FIG. 14 depicts a cross-section of another exemplary embodiment of a noise attenuation device 800 to illustrate another advantage of the proposed design. In the example of FIG. 14, the noise attenuation device 800 is disposed at one of the inlet/outlets (e.g., the inlet/outlets 806, 808) of the fluid coupling 802. Examples of the attenuation device 800 can include a pair of plate assemblies 816, which receive flow from upstream (or downstream) of the fluid coupling 802. This configuration is helpful to attenuate noise on fluid couplings that cannot integrate the noise attenuation device 800, as shown in one or more examples above.

[0041] In view of the foregoing, the improvements in noise attenuation disclosed herein simplify construction of the attenuating device, while provide a robust, cost- effective, and retrofittable package design. The embodiments apply multi-turn techniques to reduce energy in a working fluid without expanding the working envelope of the fluid couplings in which these proposed devices are found.

[0042] As used herein, an element or function recited in the singular and proceeded with the word "a" or "an" should be understood as not excluding plural said elements or functions, unless such exclusion is explicitly recited. Furthermore, references to "one embodiment" of the claimed invention should not be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. [0043] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.