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CN-122028987-A - Method for manufacturing a single set refiner disc and refiner disc manufactured by said method

CN122028987ACN 122028987 ACN122028987 ACN 122028987ACN-122028987-A

Abstract

A single set manufacturing method of a refiner disc comprising a plurality of ribs (204,404,1102,1701,1801,2004,2104,2204), wherein the ribs (204,404,1102,1701,1801,2004,2104,2204) are configured with a blade (205,503,603,703,801,901,1103,1303,1503,1603,1703,2003,2103,2203) and the blade (205,503,603,703,801,901,1103,1303,1503,1603,1703,2003,2103,2203) is configured with a base plate (300) to join the disc (200,400,2000,2100,2200) using positive locking means. Grooves (202,401,505,605,705,802,902,1001aa,1001ba,1001ca,1001da,1001ea,1001fa,1001ga,1301,1602,1702,2002,2102), are formed using a single set process to efficiently manufacture the disc (200,400,2000,2100,2200) with robust structural integrity for efficient pulp refining applications.

Inventors

  • Kishor Chandra Shekhar Desada
  • Amor Sharad Chandra Thakur
  • Shalendra Omprakash Kojalei
  • Rajendra Suresh Sinde
  • Arthur Vital Sinde
  • Ravendra Guruxidapa Hongdekar

Assignees

  • 帕拉森机械(印度)私人有限公司

Dates

Publication Date
20260512
Application Date
20241129
Priority Date
20240911

Claims (20)

  1. 1. A refiner disc (200,400,2000,2100,2200) comprising: An o-substrate (300); o plurality of ribs (204,404,1102,1701,1801,2004,2104,2204), and O a plurality of abrasive sheets (205,503,603,703,801,901,1103,1303,1503,1603,1703,2003,2103,2203); Wherein the plurality of ribs (204,404,1102,1701,1801,2004,2104,2204) are configured with the blade (205,503,603,703,801,901,1103,1303,1503,1603,1703,2003,2103,2203) and the blade (205,503,603,703,801,901,1103,1303,1503,1603,1703,2003,2103,2203) is configured with the base plate (300) to form the refiner disc (200,400,2000,2100,2200); Wherein the blade (205,503,603,703,801,901,1103,1303,1503,1603,1703,2003,2103,2203) comprises a plurality of grooves (202,401,505,605,705,802,902,1001aa,1001ba,1001ca,1001da,1001ea,1001fa,1001ga,1301,1602,1702,2002,2102), formed across the surface of the blade (205,503,603,703,801,901,1103,1303,1503,1603,1703,2003,2103,2203), each of the grooves (202,401,505,605,705,802,902,1001aa,1001ba,1001ca,1001da,1001ea,1001fa,1001ga,1301,1602,1702,2002,2102) being parallel to each other and configured to receive the ribs (204,404,1102,1701,1801,2004,2104,2204), and each of the grooves forming narrow channels or valleys (403, 511 ab, 511 bb, 511 cb, 511 db, 511 eb, 511 fb, 511 gb, 2210) between each of the ribs (204,404,1102,1701,1801,2004,2104,2204) on the surface of the blade (205,503,603,703,801,901,1103,1303,1503,1603,1703,2003,2103,2203); Wherein the plurality of grooves (202,401,505,605,705,802,902,1001aa,1001ba,1001ca,1001da,1001ea,1001fa,1001ga,1301,1602,1702,2002,2102) comprises at least one outlet groove (201, 402,504,604,704,1001a-g,1100,1302,1401,1501,1601,2001 a,2101 a, 2201), the outlet groove (201, 402,504,604,704,1001a-g,1100,1302,1401,1501,1601,2001 a,2101 a, 2201) accommodating a rib (205,503,603,703,801,901,1103,1303,1503,1603,1703,2003,2103,2203) being capable of forming a bridge between two consecutive grooves (202,401,505,605,705,802,902,1001aa,1001ba,1001ca,1001da,1001ea,1001fa,1001ga,1301,1602,1702,2002,2102) in the narrow channel or valley (403, 1001ab,1001bb,1001 db,1001eb,1001fb, 2210), wherein the plurality of grooves (202,401,505,605,705,802,902,1001aa,1001ba,1001ca,1001da,1001ea,1001fa,1001ga,1301,1602,1702,2002,2102) and the outlet groove (201, 402,504,604,704, 1100, 1401,1501, 2001, 2101a, 2201) are formed by a single forming process.
  2. 2. The refiner disc (200,400,2000,2100,2200) of claim 1, wherein the grooves (202,401,505,605,705,802,902,1001aa,1001ba,1001ca,1001da,1001ea,1001fa,1001ga,1301,1602,1702,2002,2102) include the outlet grooves (101,201,402,504,604,704,1001a-g,1100,1302,1401,1501,1601,2001,2101-2,2201-2202,2105a-,2101a,21001), configured such that the ribs (204,404,1102,1701,1801,2004,2104,2204) and flow restrictors (1101,1900,2008,2108,2208) can be securely inserted into and locked with the blade (205,503,603,703,801,901,1103,1303,1503,1603,1703,2003,2103,2203) from one side of the blade (205,503,603,703,801,901,1103,1303,1503,1603,1703,2003,2103,2203).
  3. 3. The refiner disc (200,400,2000,2100,2200) of claim 1, wherein the grooves (202,401,505,605,705,802,902,1001aa,1001ba,1001ca,1001da,1001ea,1001fa,1001ga,1301,1602,1702,2002,2102) are parallel and evenly spaced across the surface of the blade to ensure even distribution of ribs (104,204,404,1102,1301,1701,1801,2004,2104,2204).
  4. 4. The refiner disc (200,400,2000,2100,2200) of claim 1, wherein the grooves (202,401,505,605,705,802,902,1001aa,1001ba,1001ca,1001da,1001ea,1001fa,1001ga,1301,1602,1702,2002,2102) are machined to precise dimensions to ensure a tight fit of the ribs (104,204,404,1102,1301,1701,1801,2004,2104,2204) to maintain the structural integrity of the refiner disc (200,400,2000,2100,2200).
  5. 5. The refiner disc (200,400,2000,2100,2200) of claim 1 wherein the plates (205,503,603,703,801,901,1103,1303,1503,1603,1703,2003,2103,2203) are locked together using a plug (501,601,701) and socket (502,602,702) locking mechanism, wherein one plate (205,503,603,703,801,901,1103,1303,1503,1603,1703,2003,2103,2203) comprises a protruding plug (501,601,701) and an adjacent plate (205,503,603,703,801,901,1103,1303,1503,1603,1703,2003,2103,2203) comprises a corresponding socket (502,602,702).
  6. 6. The refiner disc (200,400,2000,2100,2200) of claim 5, wherein the protruding plug (501,601,701) and the socket (502,602,702) have a shape selected from the group consisting of pentagonal, hexagonal or trapezoidal or dovetailed, rectangular, square or U-shaped, elliptical, semicircular, curved or circular.
  7. 7. The refiner disc (100,200,400,2000,2100,2200) of claim 1, wherein the restrictor (1101,1900,2008,2108,2208) is inserted into the outlet grooves (201, 402,504,604,704,1001a-g,1100,1302,1401,1501,1601,2001 a,2101 a, 2201) on the refiner plate (205,503,603,703,801,901,1103,1303,1503,1603,1703,2003,2103,2203) such that the restrictor protrudes between adjacent ribs (204,404,1102,1701,1801,2004,2104,2204).
  8. 8. The refiner disc (100,200,400,2000,2100,2200) of claim 1, wherein the abrasive sheet (205,503,603,703,801,901,1103,1303,1503,1603,1703,2003,2103,2203) constructed with the ribs (204,404,1102,1701,1801,2004,2104,2204) and flow restrictor (1101,1900,2008,2108,2208) is secured to the base plate (300) by welding at a specific point (301) to create a strong bond with minimal material stress.
  9. 9. The refiner disc (100,200,400,2000,2100,2200) of claim 1, wherein the base plate (300) comprises a groove or recess to receive and hold in place the interlocked plates (205,503,603,703,801,901,1103,1303,1503,1603,1703,2003,2103,2203).
  10. 10. The refiner disc (100,200,400,2000,2100,2200) according to claim 1, wherein the rib (1801) comprises specific features, such as slots or notches, which enable firm insertion and stabilization of the lateral restrictor (1900 i).
  11. 11. The refiner disc (100,200,400,2000,2100,2200) of claim 1, wherein each rib (204,404,1102,1701,1801,2004,2104,2204) has a height (P), each groove (202,401,505,605,705,802,902,1001aa,1001ba,1001ca,1001da,1001ea,1001fa,1001ga,1301,1602,1702,2002,2102) has a depth (Q) that is equal to the size or depth (Q) of the blade (205,503,603,703,801,901,1103,1303,1503,1603,1703,2003,2103,2203) or greater than the height (P) of a slot (1701 a,1701 b) configured to extend below the blade (205,503,603,703,801,901,1103,1303,1503,1603,1703,2003,2103,2203) configured with the base plate (300) in a direction opposite to the direction in which the rib (204,404,1102,1701,1801,2004,2104,2204) protrudes from the groove to form a length (X).
  12. 12. The refiner disc (100,200,400,2000,2100,2200) of claim 1, wherein the outlet grooves (201, 402,504,604,704,1001a-g,1100,1302,1401,1501,1601,2001 a,2101 a, 2201) are configured in a high-level pattern to process a material flow, the high-level pattern including, but not limited to, a stepped form, an inclined form, a curved form, a single-spiral form, a double-spiral form.
  13. 13. The refiner disc (100,200,400,2000,2100,2200) according to claim 1, wherein for a single spiral (2005) configuration, a first spiral (2005 a) of the outlet groove (2001) starts at 0 ° and gradually increases to 180 ° from the input end (2006) to reach the ultimate outlet of the output end (2007), and a second spiral (2005 b) starts at 180 ° and ends at 0 ° or 360 °.
  14. 14. The refiner disc (100,200,400,2000,2100,2200) according to claim 1, wherein for a single spiral (2005) configuration, spiral (2005 a) starts at 0 ° and gradually increases to 180 ° from the input end (2006) to reach the ultimate outlet of the output end (2007), and a second spiral (2005 b) starts at 180 ° and ends at 0 ° or 360 ° to complete the 360 ° circumference of the refiner disc (2000) with the single spiral (2005).
  15. 15. The refiner disc (100,200,400,2000,2100,2200) according to claim 1, wherein in case of a double helix (2105) configuration of the outlet groove (2101), a first helix (2105 a) starts at 0 ° and ends at 180 °, the first helix gradually increasing from the input end (2106) towards the output end (2107), and a second helix (2105 b) starts immediately at 180 ° and ends at 0 ° or 360 °, the second helix following a similar pattern as the first helix (2105 a), while a third helix (2105 c) starts at 90 ° and ends at 270 °, the third helix gradually increasing from the input end (2106) towards the output end (2107), and a fourth helix (2105 d) starts at 270 ° and ends at 90 °, such that the third helix (2105 c) and the fourth helix (2105 d) start at the middle of the first helix (2105 a) and the second helix (2105 b) and/or pass through the circumference of the double helix (2105) to complete the refiner disc (2100).
  16. 16. The refiner disc (100,200,400,2000,2100,2200) of claim 1, wherein the grooves (202,401,505,605,705,802,902,1001aa,1001ba,1001ca,1001da,1001ea,1001fa,1001ga,1301,1602,1702,2002,2102) which do not intersect the spiral (2005,2105) are connectable with partial outlet grooves (2001 a,21001 a).
  17. 17. The refiner disc (100,200,400,2000,2100,2200) according to claim 1, wherein partial outlet grooves (2001 a,21001 a) are made along the output end (2007,2107) for said grooves that do not intersect the spiral (2005,2105) (202,401,505,605,705,802,902,1001aa,1001ba,1001ca,1001da,1001ea,1001fa,1001ga,1301,1602,1702,2002,2102).
  18. 18. The refiner disc (100,200,400,2000,2100,2200) of claim 1, wherein the flow restrictor (1101,1900,2008,2108,2208) may or may not be configured in a partial outlet groove (2001 a,21001 a).
  19. 19. The refiner disc (100,200,400,2000,2100,2200) of claim 1, wherein the flow restrictor (1101,1900,2008,2108,2208) is configured in a partial outlet groove (2001 a,2101 a) to ensure that only one of the flow restrictor (1101,1900,2008,2108,2208) and the partial flow restrictor (268 a,2108 a) is present between the groove (202,401,505,605,705,802,902,1001aa,1001ba,1001ca,1001da,1001ea,1001fa,1001ga,1301,1602,1702,2002,2102) or the rib (204,404,1102,1701,1801,2004,2104,2204) when the outlet groove (201, 402,504,604,704, 521 a-g,1100,1302,1401,1501,1601,2001,2101,2201) or the partial outlet groove (2001 a,2101 a) spans either of a single spiral (2005 a,2005 b) and a double spiral (2105 a,2105b,2105c,2105 d).
  20. 20. The refiner disc (100,200,400,2000,2100,2200) of claim 1, wherein the outlet groove (2201) is shaped in a curved pattern (2205) starting from an input end (2206) to an output end (2207) of the same sector (2202 a) with a specified length (2210) to complete the curved pattern (2205) within the same sector (2202 a), the specified length gradually increasing with increasing trajectory of the curved pattern (2205) of the outlet groove (2201).

Description

Method for manufacturing a single set refiner disc and refiner disc manufactured by said method Technical Field The present disclosure relates to the field of refining apparatuses, and more particularly to an apparatus for refining of pulp. Background Conventional refiner discs are typically manufactured using casting, welding or milling processes. Refiner discs produced by casting tend to be bulky and require draft angles to remove the refiner disc from the casting mould. Furthermore, the draft angle increases the rib thickness, which reduces the cutting edge length of the refiner disc and the overall material working surface, eventually reducing the efficacy and efficiency of the refining process. In contrast, refiner discs manufactured by milling processes can be designed without draft angles to achieve the desired cutting edge length with fine or shank features to increase the refining surface. However, this process requires intensive machining of grooves and ribs, which significantly increases the machining costs and increases the complexity of joining the refiner discs. This complexity results in a higher product reject rate and further increases the cost of the refiner disc. Further, in welded refiner discs, the discs consist of several parts, including ribs, abrasive sheets and base plates. Constructed on a plurality of ribs together with the refiner plates, which are then assembled to a single base plate to form a welded refiner disc. The construction of a plurality of ribs within the blade requires the formation of an equal number of grooves in the blade, which requires precise machining to ensure a strong and rigid configuration. This accuracy further increases the tooling costs of the abrasive sheet. When the ribs and grooves are profiled or curved, the machining becomes more complex, resulting in higher machining costs and increased scrap rates. Manufacturing defects such as profile non-uniformity, groove uniformity problems, and plate integrity problems become more common if the grooves are not machined in a single machining setup. In addition, the grooves must be machined to form a uniform bottom surface opposite the rib and blade configuration to ensure complete assembly with the base plate. The complexity is further increased when the flow restrictor needs to be integrated into the refiner disc, wherein separate grooves have to be machined into the blade to accommodate the flow restrictor, which increases the overall complexity and cost of the refiner disc. Furthermore, the restrictor must be designed to facilitate smooth and efficient pulp refining without causing clogging or blockage between the pair of refiner discs. An improper design or configuration of the flow restrictor increases the refining load, resulting in higher power consumption and shortened refiner disc life. In another embodiment, the restrictor must be precisely grooved in accordance with the flow of slurry through the refiner disc. This further increases the processing time, reject rate and profile complexity to significantly increase the manufacturing costs of the welded refiner disc with the restrictor. If improperly designed, the restrictor may cause unexpected refining loads or jams, thereby reducing the efficiency of the pulp refining and the overall papermaking process and increasing costs. There is therefore a technical gap that needs to be addressed by developing an efficient manufacturing method for said refiner discs. Disclosure of Invention In an embodiment, the present disclosure provides a refiner disc comprising a base plate, a plurality of ribs and a refiner plate. The plurality of ribs are configured with the blade and the blade is also configured with the base plate to collectively form the refiner disc. The abrasive sheet has a plurality of grooves formed across the surface, the plurality of grooves being parallel to one another and designed to receive the plurality of ribs, wherein the grooves comprise a plurality of outlets joined in a configuration selected from a series of patterns including, but not limited to, stepped-up, stepped-down, curved, inclined, rectilinear, undulating, spiral patterns, and various combinations thereof. The grooves are formed using a single set machining tool including, but not limited to, options such as drilling, CNC machine, laser drilling, wire cutting, and the like, or combinations thereof. In an embodiment, the present invention provides a refiner disc wherein the through groove comprises an outlet configured such that the rib and restrictor can be securely inserted and locked into the blade. In another embodiment, the present invention provides a refiner disc wherein the grooves are parallel and evenly spaced across the surface of the blade to ensure even distribution of the ribs. In a further embodiment, the invention provides a refiner disc in which the grooves are machined to precise dimensions to ensure a close fit with the ribs to maintain the structural integr