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EP-4735179-A1 - A SINGLE SETUP REFINER DISC MANUFACTURING METHOD AND REFINER DISC MADE OF SAID METHOD THEREOF

EP4735179A1EP 4735179 A1EP4735179 A1EP 4735179A1EP-4735179-A1

Abstract

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

Inventors

  • Desarda, Kishor Chandrashekhar
  • Thakur, Amol Sharadchandra
  • Khojare, Shailendra Omprakash
  • Shinde, Rajendra Suresh
  • Shinde, Atul Vitthal
  • Hundekar, Ravindra Gurusidappa

Assignees

  • Parason Machinery (India) Private Limited

Dates

Publication Date
20260506
Application Date
20241129

Claims (20)

  1. 1. A refiner disc (200, 400, 2000, 2100, 2200) comprising: o a base plate (300); o a plurality of ribs (204, 404, 1102, 1701, 1801, 2004, 2104, 2204); and O a plurality of tiles (205, 503, 603, 703, 801, 901, 1103, 1303, 1503,1603, 1703, 2003, 2103, 2203); o wherein said plurality of ribs (204, 404, 1102, 1701, 1801, 2004, 2104, 2204 ) configured with said tile (205, 503, 603, 703, 801, 901,1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) and said tile (205, 503, 603, 703, 801, 901, 1103, 1303, 1503, 1603, 1703, 2003, 2103, 2203) is configured with said base plate (300) to form said refiner disc (200, 400, 2000, 2100, 2200); O wherein said tile (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, lOOlaa, lOOlba, lOOlca, lOOlda, lOOlea, lOOlfa, lOOlga, 1301, 1602, 1702, 2002, 2102) formed across the tiles (205, 503, 603, 703, 801, 901, 1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) surface, each said groove (202, 401, 505, 605, 705, 802, 902, lOOlaa, lOOlba, lOOlca, lOOlda, lOOlea, lOOlfa, lOOlga, 1301, 1602, 1702, 2002, 2102) parallel to each other configured to accommodate said ribs (204, 404, 1102, 1701, 1801, 2004, 2104, 2204) and forms a narrow channel or valley (403, lOOlab, lOOlbb, lOOlcb, lOOldb, lOOleb, lOOlfb, lOOlgb, 2210) on the tile (205, 503, 603, 703, 801, 901, 1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) surface between each said ribs (204, 404, 1102, 1701, 1801, 2004, 2104, 2204); o wherein said plurality of grooves (202, 401, 505, 605, 705, 802, 902, lOOlaa, lOOlba, lOOlca, lOOlda, lOOlea, lOOlfa, lOOlga, 1301, 1602, 1702, 2002, 2102) comprises at least an exit groove ( 201, 402, 504, 604, 704, 1001a — g, 1100, 1302, 1401, 1501, 1601, 2001, 2001a, 2101, 2101a, 2201), said exit groove ( 201, 402, 504, 604, 704, 1001a— g, 1100, 1302, 1401, 1501, 1601, 2001, 2001a, 2101, 2101a, 2201) accommodating ribs (205, 503, 603, 703, 801, 901, 1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) appears to form a bridge between two consecutive grooves (202, 401, 505, 605, 705, 802, 902, lOOlaa, lOOlba, lOOlca, lOOlda, lOOlea, lOOlfa, lOOlga, 1301, 1602, 1702, 2002, 2102) in said narrow channel or valley (403, lOOlab, lOOlbb, lOOlcb, lOOldb, lOOleb, lOOlfb, lOOlgb, 2210)wherein said plurality of grooves (202, 401, 505, 605, 705, 802, 902, lOOlaa, lOOlba, lOOlca, lOOlda, lOOlea, lOOlfa, lOOlga, 1301, 1602, 1702, 2002, 2102) and said exit groove ( 201, 402, 504, 604, 704, 1001a— g, 1100, 1302, 1401, 1501, 1601, 2001, 2001a, 2101, 2101a, 2201) formed by means of a single setup of machining formation.
  2. 2. The refiner disc (200, 400, 2000, 2100, 2200) of claim 1, wherein said groove (202, 401, 505, 605, 705, 802, 902, lOOlaa, lOOlba, lOOlca, lOOlda, lOOlea, lOOlfa, lOOlga, 1301, 1602, 1702, 2002, 2102) includes said exit groove (101,201,402, 504, 604, 704, 1001a— g, 1100, 1302, 1401, 1501, 1601, 2001, 2101-2, 2201- 2202,2105a-, 2101a, 21001) configured to allow secure insertion and locking of the rib (204, 404, 1102, 1701, 1801, 2004, 2104, 2204) and a flow restrictor (1101, 1900, 2008, 2108, 2208) with said tile (205, 503, 603, 703, 801, 901,1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) from one side of said tile (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, lOOlaa, lOOlba, lOOlca, lOOlda, lOOlea, lOOlfa, lOOlga, 1301, 1602, 1702, 2002, 2102) are parallel and evenly spaced across the tile surface to ensure uniform 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, lOOlaa, lOOlba, lOOlca, lOOlda, lOOlea, lOOlfa, lOOlga, 1301, 1602, 1702, 2002, 2102) are machined with precise dimensions to ensure a tight fit for the ribs (104, 204, 404, 1102, 1301, 1701, 1801, 2004, 2104, 2204), maintaining 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 tiles (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) type locking mechanism, wherein one tile (205, 503, 603, 703, 801, 901,1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) includes a protruding plug (501, 601, 701) and an adjacent tile (205, 503, 603, 703, 801, 901,1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) includes a corresponding socket (502, 602, 702) .
  6. 6. The refiner disc (200, 400, 2000, 2100, 2200) of claim 5, wherein said protruding plug (501, 601, 701) and socket (502, 602, 702) comprises the shape from the group consisting of pentagonal, hexagonal or trapezoidal or dovetail, rectangular, square or U-shaped, elliptical, semi-circular, curved or circular.
  7. 7. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein said flow restrictor (1101, 1900, 2008, 2108, 2208) inserted into the exit groove (201, 402, 504, 604, 704, 1001a— g, 1100, 1302, 1401, 1501, 1601, 2001, 2001a, 2101, 2101a, 2201) on the tile (205, 503, 603, 703, 801, 901,1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) in a manner to projects 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 said tiles (205, 503, 603, 703, 801, 901,1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) configured with said ribs (204, 404, 1102, 1701, 1801, 2004, 2104, 2204) and said flow restrictor (1101, 1900, 2008, 2108, 2208) secured to said base plate (300) by welding at specific points (301), creating a strong bond with minimal material stress.
  9. 9. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein said base plate (300) includes grooves or recesses to accommodate and hold the interlocked said tiles (205, 503, 603, 703, 801, 901,1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) in place.
  10. 10. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein the ribs (1801) include specific features, such as slots or notches, that allow secure insertion and stabilization of the lateral flow restrictor (1900i).
  11. 11. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein each said ribs (204, 404, 1102, 1701, 1801, 2004, 2104, 2204) has a height (P) and each said groove (202, 401, 505, 605, 705, 802, 902, lOOlaa, lOOlba, lOOlca, lOOlda, lOOlea, lOOlfa, lOOlga, 1301, 1602, 1702, 2002, 2102) has depth (Q), which may be equal in dimension or the depth (Q) of said tiles (205, 503, 603, 703, 801, 901,1103, 1303, 1503,1603, 1703, 2003, 2103, 2203), or may be larger than said height (P) of said slot (1701a, 1701b) configure without extending below said tiles (205, 503, 603, 703, 801, 901,1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) along surface configuring with said base plate (300) in the opposite direction of said rib (204, 404, 1102, 1701, 1801, 2004, 2104, 2204) protrusion from said groove to form a length (X).
  12. 12. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein said exit grooves (201, 402, 504, 604, 704, 1001a— g, 1100, 1302, 1401, 1501, 1601, 2001, 2001a, 2101, 2101a, 2201) configured in advanced patterns which comprises but not limits to stepped, inclined, curved, single spiral, double spiral, forms to process the flow of material.
  13. 13. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein a first spiral (2005a) of said exit groove (2001) starts at 0° from said input (2006) and gradually increases till 180° to reach the extreme outlet of said output end (2007) and said second spiral (2005b) start from 180° and ends at 0° or 360° for said single spiral (2005) configuration.
  14. 14. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein said spiral (2005a) starts at 0° from said input (2006) and gradually increases till 180° to reach the extreme outlet of said output end (2007) and said second spiral (2005b) start from 180° and ends at 0° or 360° for said single spiral (2005) configuration in order to complete 360° periphery of said refiner disc (2000) by said single spiral (2005).
  15. 15. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein in case of said dual spiral (2105) configuration of said exit grooves (2101) a first spiral (2105a) starts at 0° to end at 180° gradually increasing from an input end (2106) towards an output end (2107) and a second spiral (2105b) starts immediately from 180° to end at 0° or 360° following a similar pattern as of said first spiral (2105a), whereas, a third spiral (2105c) starts 90° to end at 270° gradually increasing from an input end (2106) towards an output end (2107) and a fourth spiral (2105d) starts from 270° to ends at 90° in a manner said third spiral (2105c) and said fourth spiral (2105d) start from the middle and/or the halfway mark of said first spiral (2105a) and said second spiral (2105b) in order to complete 360° periphery of said refiner disc (2100) by said dual spiral (2105) configuration.
  16. 16. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein said groove (202, 401, 505, 605, 705, 802, 902, lOOlaa, lOOlba, lOOlca, lOOlda, lOOlea, lOOlfa, lOOlga, 1301, 1602, 1702, 2002, 2102) does not cross with said spiral (2005, 2105) can be connected with a local exit groove (2001a, 21001a).
  17. 17. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein said local exit grooves (2001a, 21001a) manufactured along said output end (2007, 2107) for the grooves (202, 401, 505, 605, 705, 802, 902, lOOlaa, lOOlba, lOOlca, lOOlda, lOOlea, lOOlfa, lOOlga, 1301, 1602, 1702, 2002, 2102) which do not cross said spiral (2005, 2105).
  18. 18. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein said flow restrictor (1101, 1900, 2008, 2108, 2208) may or may not be configured in said local exit grooves (2001a, 21001a).
  19. 19. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein said flow restrictor (1101, 1900, 2008, 2108, 2208) configured in said local exit groove (2001a, 2101a) in a manner to ensure the appearance of only one of said flow restrictors (1101, 1900, 2008, 2108, 2208) or said local flow restrictor (2008a, 2108a) between said groove (202, 401, 505, 605, 705, 802, 902, lOOlaa, lOOlba, lOOlca, lOOlda, lOOlea, lOOlfa, lOOlga, 1301, 1602, 1702, 2002, 2102) or said rib (204, 404, 1102, 1701, 1801, 2004, 2104, 2204) in said exit grooves (201, 402, 504, 604, 704, 1001a— g, 1100, 1302, 1401, 1501, 1601, 2001, 2101, 2201) or said local exit grooves (2001a, 2101a) across any of said single spiral (2005a, 2005b) or said dual spiral (2105a, 2105b, 2105c, 2105d).
  20. 20. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein said exit grooves (2201) formed in a curved pattern (2205) commenced at a specified length (2210) from an input end (2206) and gradually increases in accordance with the increase in the trajectory of said curved pattern (2205) of said exit grooves (2201) to an output end (2207) of same sector (2202a) in order to complete said curved pattern (2205) within same sector (2202a) .

Description

A SINGLE SETUP REFINER DISC MANUFACTURING METHOD AND REFINER DISC MADE OF SAID METHOD THEREOF FIELD OF INVENTION The present disclosure relates to the field of refining equipment, and more specifically, to equipment used in refining of the pulp for paper. BACKGROUND OF THE INVENTION Conventional refiner discs are typically manufactured using casting, welding, or milling processes. Refiner discs produced through casting tend to be bulky and require a draft angle to eject them from the casting mold. Further, said draft angle increases the thickness of the rib, which reduces the cutting-edge length and the overall material processing surface of the refiner disc, ultimately decreasing the efficacy and efficiency of the refining process. In contrast, refiner discs manufactured through the milling process can be designed without a draft angle, allowing for the intended cutting-edge length with the fine bar or micro-fine bar features in order to increase the refining surface. However, this process requires intensive machining of grooves and ribs, which significantly raises the machining cost and increases the complexity of articulating the refiner disc. This complexity leads to a higher product rejection rate and further escalates the cost of said refiner disc. Moreover, in welded refiner discs, the disc is composed of multiple components, including ribs, tiles, and a base plate. A plurality of ribs are configured with the tiles, and these tiles are then assembled onto a single base plate to form the welded refiner disc. The configuration of numerous ribs within the tiles requires the creation of an equal number of grooves in the tiles, demanding precise machining to ensure a robust and rigid configuration. This precision further increases the machining cost of the tiles. The machining becomes even more intricate when the ribs and grooves are profiled or curved, leading to higher machining costs and an increased rejection rate. Manufacturing flaws such as profile unevenness, groove uniformity issues, and tile integrity problems become more common if said grooves are not machined in a single machining setup. Additionally, said grooves must be machined to produce a uniform bottom surface opposite to the rib and tile configuration to ensure an intact assembly with the base plate. The complexity is further heightened when flow restrictors need to be integrated into the refiner disc, wherein the separate grooves must be machined into the tiles in order to accommodate the flow restrictor, which adds to the overall complexity and cost for said refiner disc. Further, said flow restrictor must be designed to facilitate streamlined and effective slurry refining without causing blockages or choking between the paired refiner discs. An inappropriate design or configuration of said flow restrictor can increase the refining load, leading to higher power consumption and reduced refiner disc life. In another embodiment, precise grooves must be machined for said flow restrictor in accordance with the slurry flow across said refiner disc. This further increases machining time, rejection rates, and profile complexity in order to dramatically driving up the manufacturing cost of said welded refiner disc with said flow restrictor. If not properly designed, said flow restrictor may cause unintended refining loads or blockages, reducing the efficiency and increasing the cost of the pulp refining and overall paper-making process. Thus, a technological gap exists that needs to be addressed through the development of effective manufacturing methods for said refiner discs. SUMMARY OF THE INVENTION In an embodiment, the present disclosure provides a refiner disc comprising a base plate, a plurality of ribs, and a tile. Said plurality of ribs is configured with said tile, and said tile is further configured with said base plate to collectively form said refiner disc. Said tile features a plurality of grooves formed across the surface, which are parallel to each other and designed to accommodate said plurality of ribs wherein said grooves include multiple exits, which are articulated in a configuration selected from a range of patterns which includes but not limits to step-up, step-down, curved, inclined, inline, up-down, spiral, and various combinations thereof. Said grooves are created using a single setup of machining tools, which includes but not limits to options such as a drilling machine, CNC machine, laser drilling, wire cutting, etc., or combinations thereof. In an embodiment, the present invention provides a refiner disc wherein the through groove includes an exit configured to allow secure insertion and locking of the rib and flow restrictor into the tile. In another embodiment, the present invention provides a refiner disc wherein the grooves are parallel and evenly spaced across the tile surface to ensure uniform distribution of ribs. In further embodiment, the present invention provides a refiner disc wherein the grooves are