Note: Descriptions are shown in the official language in which they were submitted.
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APPARATUS AND METHOD FOR PROCESSING WOOD FIBERS
RELATED APPLICATIONS
This application is a continuation-in-part of U.S. Patent Application No.
15/860,055, filed
January 2, 2018 (Attorney Docket No. TEC-119945-US), which is related to U.S.
Patent
Application No. 15/860,006, filed January 2, 2018 (Attorney Docket No. TEC-
120257-US).
Further this application claims dual priority to U.S. Patent Application No.
15/860,006.
FIELD OF THE INVENTION
The present disclosure relates generally to processing wood fibers in a
refiner and more
particularly to an apparatus and method for refining wood fibers and breaking
up fiber bundles.
BACKGROUND OF 'THE INVENTION
Disc-type refiners have traditionally been used to process wood fibers in a
step of a paper
product making process. Such refiners include first and second refining
members having a refining
space therebetween. Each of the first and second refining members include a
plurality of refiner
bars separated by refiner grooves, in which the refiner bars define cutting
surfaces for cutting the
wood fibers. During operation, at least one of the first and second refining
members is rotated
relative to the other, in which rotation of the cutting surfaces of the
refiner bars cut wood fibers
being processed in the refiner. Once the wood fibers are processed in the
refiner, the processed
wood fibers may be further processed in subsequent paper product making
processes to produce
paper products. In some instances, the wood fibers may undergo additional
processing, such as in
a separate tickler refiner or deflaker. As is known in the art, conical
refiners operate in the same
manner except that the refining members are positioned on a conical surface
instead of a disc.
SUMMARY OF THE INVENTION
In accordance with a first aspect of the present invention, a refining member
for a pulp
refiner is provided. The refining member comprises a refining body including a
refining surface
comprising first refiner bars separated by first refiner grooves and extending
from a first radially
inward position to a first radially outward position on the refining surface
and second refiner bars
separated by second refiner grooves and extending from a second radially
inward position to a
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second radially outward position on the refining surface, in which the second
radially outward
position is nearer to an outermost part of the refining body than the first
radially outward position.
The first refiner bars have a first height extending upward from a floor of an
adjacent first refiner
groove, and the second refiner bars have a second height extending upward from
a floor of an
adjacent second refiner groove. The second height is a minimum height of the
second refiner bars
and is spaced apart from the second radially inward position, with the second
height being at least
about 0.35 mm less than the first height. The first refiner bars are adapted
to refine wood fibers,
and the second refiner bars are adapted to break up fiber bundles.
The minimum height of the second refiner bars may be adjacent to the second
radially
outward position.
The first height may be substantially constant along a longitudinal length of
the first refiner
bars.
The first height may be from about 4.0 mm to about 10.0 mm. The second height
may be
from about 0.35 mm to about 7A) mm less than the first height, or from about
0.7 mm to about 7.0
mm less than the first height.
The second refiner bars may be integral with the first refiner bars such that
the second
refiner bars extend from the first radially outward position to the second
radially outward position
Each of the second refiner bars may slope substantially continuously downward
along at least a
portion of each second refiner bar extending between the first radially
outward position and the
second radially outward position.
At least a portion of the first refiner grooves may be provided with dams.
The first height of the first refiner bars may comprise a first maximum
height, and the
second refiner bars may comprise a second maximum height extending upward from
the floor of
the adjacent second refiner groove, in which a radially outer portion of each
of the first refiner bars
may comprise a step-down from the first maximum height to the second maximum
height and in
which the second maximum height may be at least about 1.5 mm less than the
first maximum
height.
The refining member may further comprise third refiner bars separated by third
refiner
grooves and fourth refiner bars separated by fourth refiner grooves. Each of
the third refiner bars
may extend to a third radially outward position on the refining surface, and
each of the fourth
refiner bars may extend to a fourth radially outward position on the refining
surface that is nearer
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to the outermost part of the refining body than the third radially outward
position. The third refiner
bars may have a third height extending upward from a floor of an adjacent
third refiner groove,
and the fourth refiner bars may have a fourth height extending upward from a
floor of an adjacent
fourth refiner groove. The fourth height may be a minimum height of the fourth
refiner bars and
may be adjacent to the fourth radially outward position. The fourth height may
be at least about
0.35 mm less than the third height. The third refiner bars may be adapted to
refine wood fibers,
and the fourth refiner bars may be adapted to break up fiber bundles.
The third refiner bars may be integral with the second refiner bars such that
the third refiner
bars extend from the second radially outward position to the third radially
outward position, and
the fourth refiner bars may be integral with the third refiner bars such that
the fourth refiner bars
extend from the third radially outward position to the fourth radially outward
position.
The third height of the third refiner bars may comprise a third maximum
height, and the
fourth refiner bars may comprise a fourth maximum height extending upward from
the floor of the
adjacent fourth refiner groove, in which a radially outer portion of each of
the third refiner bars
may comprise a step-down from the third maximum height to the fourth maximum
height and in
which the fourth maximum height may be at least about 1.5 mm less than the
third maximum
height.
In accordance with a second aspect of the present disclosure, a pulp refiner
is provided.
The pulp refiner comprises. a frame, at least a first pair of refining
members, and a rotor. The
refining members comprise a first refining member associated with the frame
and comprising a
first refining body and a second refining member associated with the frame and
comprising a
second refining body. The first refining body includes a first refining
surface comprising: first
refiner bars separated by first refiner grooves and extending from a first
radially inward position
on the refining surface to a first radially outward position on the refining
surface, and second
refiner bars separated by second refiner grooves and extending from a second
radially inward
position on the refining surface to a second radially outward position on the
refining surface, with
the second radially outward position being nearer to an outermost part of the
refining body than
the first radially outward position. The first refiner bars have a first
height extending upward from
a floor of an adjacent first groove, and the second refiner bars have a second
height extending
upward from the adjacent second groove floor. The second height is a minimum
height of the
second refiner bars and is spaced apart from the second radially inward
position. The second
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height is at least about 035 mm less than the first height. The second
refining member includes a
second refining surface comprising second member refiner bars separated by
second member
refiner grooves. The first refining member is spaced from the second refining
member to define a
refining space therebetween, in which at least a portion of the second member
refiner bars are
positioned so as to be across from the second refiner bars to define a gap
between the portion of
the second member refiner bars and the second refiner bars. The rotor is
coupled to one of the first
refining member or the second refining member such that rotation of the rotor
effects movement
of the one of the first or the second refining member relative to the other.
When a slurry of wood
pulp comprising wood fibers is supplied to the frame, the wood pulp slurry
passes through the
refining space such that a significant number of the wood fibers in the wood
pulp slurry are refined
and a plurality of wood fiber bundles in the wood pulp slurry are separated.
The minimum height of the second refiner bars may be adjacent to the second
radially
outward position.
The first height may be substantially constant along a longitudinal length of
the first refiner
bars.
The second height may be at least about 0.7 mm less than the first height.
The first height of the first refiner bars may comprise a first maximum
height, and the
second refiner bars may comprise a second maximum height extending upward from
the floor of
the adjacent second refiner groove, in which a radially outer portion of each
of the first refiner bars
may comprise a step-down from the first maximum height to the second maximum
height and in
which the second maximum height may be at least about 1.5 mm less than the
first maximum
height.
The second member refiner bars may comprise: first refiner bar elements
extending from
a first radially inward position to a first radially outward position on the
second refining surface,
and second refiner bar elements extending to a second radially outward
position on the second
refining surface that is nearer to an outermost part of the second refining
body than the first radially
outward position. The first refiner bar elements may have a first bar height
extending upward from
a floor of an adjacent groove, and the second refiner bar elements may have a
second bar height
extending upward from the adjacent groove floor. The second bar height may be
a minimum
height of the second refiner bar elements and may be adjacent to the second
radially outward
position. The second bar height may be at least about 0.35 mm less than the
first bar height.
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In accordance with a third aspect of the present disclosure, a method for
processing wood
fibers is provided. The method comprises providing a refiner comprising at
least a first pair of
refining members. The refining members comprise: a first refining member
comprising a first
refining body and a second refining member comprising a second refining body.
The first refining
body includes a first refining surface comprising: first refiner bars
separated by first refiner grooves
and having a first height extending upward from a floor of an adjacent first
refiner groove, and
second refiner bars separated by second refiner grooves and having a second
height extending
upward from a floor of an adjacent second refiner groove. The second refining
body includes a
second refining surface comprising second member refiner bars separated by
second member
refiner grooves. The first refining member is spaced from the second refining
member to define a
refining space therebetween and at least a portion of the second member
refiner bars are positioned
so as to be across from the second refiner bars to define a gap between the
portion of the second
member refiner bars and the second refiner bars. The method further comprises:
rotating at least
one of the first refining member or the second refining member such that the
first and second
refining members move relative to one another; supplying a slurry of wood pulp
comprising wood
fibers to the refiner such that the slurry passes through the refining space;
and applying axial
pressure to at least one of the first refining member or the second refining
member as the slurry is
supplied. The gap between the portion of the second member refiner bars and
the second refiner
bars increases along at least a section of the second refiner bars in a
direction extending from a
first radially inward position toward a first radially outward position on the
first refining surface.
At least a portion of wood fiber bundles passing through the gap are
separated.
The second height may be a minimum height of the second refiner bars and may
be adjacent
to the first radially outward position. The second height may be at least
about 0.35 mm less than
the first height.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing out and
distinctly
claiming the present invention, it is believed that the present invention will
be better understood
from the following description in conjunction with the accompanying Drawing
Figures, in which
like reference numerals identify like elements, and wherein:
FIG. 1 is a schematic, partial cross-sectional view of a disc refiner;
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FIGS. 2 and 3 are plan views of a first and a second refining body,
respectively;
FIGS. 4A and 4B are plan views of a section of a refining surface of the first
refining body
of FIG. 2;
FIGS. 5A and 5B are plan views of a section of a refining surface of the
second refining
body of FIG. 3;
FIG. 6A is a partial cross-sectional view of a refining body taken along line
6A-6A in
FIGS. 4A and 5A;
FIG. 6B is a partial cross-sectional view of a refining body taken along line
6B-6B in
FIGS. 48 and 58;
FIG. 7 is a partial cross-sectional view taken along line 7-7 in FIGS. 4A, 4B,
5A, and 5B;
FIGS. 8 and 9 are partial cross-sectional views of a refiner bar on a first
refining body that
is spaced apart and positioned above a corresponding refiner bar on a second
refining body;
FIGS. 10 and 11 are plan views of portions of a first and a second refining
body,
respectively, comprising a plurality of radially extending pie-shaped
segments;
FIGS. 12A and 12B are partial cross-sectional views of refiner bars from the
pie-shaped
segments of FIGS. 10 and 11, in which one refining body is spaced apart and
positioned above
another refining body;
FIGS. 13 and 14 are plan views of a first and a second refining body,
respectively,
comprising teeth;
FIG. 15 is a plan view of a section of a refining surface of the first
refining body of FIG.
13;
FIG. 16 is a plan view of a section of a refining surface of the second
refining body of FIG.
14;
FIG. 17 is a partial cross-sectional view of a refiner bar and tooth on a
first refining body
that is spaced apart and positioned above a second refining body comprising a
refiner bar and teeth;
FIG. 18 is a flowchart illustrating an exemplary method for processing wood
fibers;
FIG. 19A a partial cross-sectional view of a refining body similar to FIG. 6A;
FIG. 19B is a partial cross-sectional view of a refining body similar to FIG.
68; and
FIG. 20 is a flowchart illustrating another exemplary method for processing
wood fibers.
DETAILED DESCRIPTION OF THE INVENTION
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In the following detailed description of the preferred embodiments, reference
is made to
the accompanying drawings that form a part hereof, and in which is shown by
way of illustration,
and not by way of limitation, specific preferred embodiments in which the
invention may be
practiced. It is to be understood that other embodiments may be utilized and
that changes may be
made without departing from the spirit and scope of the present invention.
FIG. 1 illustrates a schematic, partial cross-sectional view of a disc refiner
10 according to
the present disclosure. The disc refiner 10 comprises a housing with a first
housing section 12 and
a second housing section 14 that may be bolted or otherwise attached fixedly
together. The
housing sections 12, 14 define an inlet 16, an outlet 18, and a refiner inner
cavity 64 that contains
one or more pairs of refining members. The embodiment shown in FIG. 1 is a
double-disc refiner
10 comprising two pairs of refining members, e.g., a first refining member 20
paired with a second
refining member 30 and a third refining member 40 paired with a fourth
refining member 50. The
first refining member 20 comprises a first refining body 22 with a first
refining surface 24, and the
second refining member 30 comprises a second refining body 32 with a second
refining surface
34. The third refining member 40 comprises a third refining body 42 and a
third refining surface
44, and the fourth refining member 50 comprises a fourth refining body 52 and
a fourth refining
surface 54 Each of the refining members 20, 30, 40, 50 are associated with a
main support frame
comprising a fixed support frame 66 secured to the first housing section 12
and a movable support
frame 68, as described herein.
The first, second, third, and fourth refining bodies 22, 32, 42, 52 may be
generally disc-
shaped with substantially identical outer diameters (see FIGS. 2 and 3). The
first and second
refining members 20, 30 are arranged such that the first refining surface 24
faces the second
refining surface 34, and the third and fourth refining members 40, 50 are
arranged such that the
third refining surface 44 faces the fourth refining surface 54. The first
refining member 20 is
spaced apart from the second refining member 30 to define a first refining
space 60 between the
respective refining surfaces 24, 34. The third refining member 40 is spaced
apart from the fourth
refining member 50 to define a second refining space 62 between the respective
refining surfaces
44, 54. The disc refiner 10 may have a structure similar to the one
illustrated in U.S. Patent
Application Publication No. 2006/0037728 Al, the disclosure of which is
incorporated herein by
reference.
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In the embodiment shown in FIG. 1, the first and fourth refining members 20,
50 are
stationary, and the second and third refining members 30,40 rotate relative to
the first and fourth
refining members 20, 50. The first refining member 20 may be fixed to the
support frame 66 by
bolts or other suitable fasteners (not shown). The second and third refining
members 30, 40 may
be attached to a support 70 that is coupled to and extends radially outwardly
from a rotatable shaft
72. The support 70 is coupled to the shaft 72 so as to rotate with the shaft
72 and is also axially
movable along the shaft 72. The shaft 72 is driven by a first motor 74 such
that the support 70 and
the second and third refining members 30, 40 rotate with the shaft 72 during
operation of the disc
refiner 10. The shaft 72 has a central axis 72A that is generally coaxial with
an axis of rotation of
the second and third refining members 30, 40. The shaft 72 may be rotatably
mounted to the fixed
support frame 66 such that the first and second refining members 30, 40 are
associated with the
main support frame. The support 70 may be movable axially along the shaft 72,
e.g., substantially
along the central axis 72A, relative to the first and fourth refining members
20, 50, as described
herein. The fourth refining member 50 may be fixed to the movable support
frame 68 by bolts or
other suitable fasteners (not shown). Thus, the support 70 and the shaft 72
may define a rotor
associated with the main support frame such that the second and third refining
members may define
rotating rotor members, and the first and fourth refining members 20, 50 may
define non-rotating
stator members. Rotation of the rotor effects movement of the second and third
refining members
30, 40 relative to the first and fourth refining members 20, 50, respectively.
The movable support frame 68 may be mounted in the second housing section 14
and is
coupled to a second motor 76, which may comprise a reversible electric motor,
which is fixed in
position. The second motor 76 moves the movable support frame 68 in a
substantially horizontal
(i.e., axial) direction shown by arrow A The refiner 10 may comprise, for
example, a jack screw
(not shown) coupled to the second motor 76 and the movable support frame 68,
which second
motor 76 may rotate the jack screw to move the movable support frame 68 to
which is attached,
for example, the fourth refining member 50. This movement adjusts the size of
the gaps, i.e., the
first and second refining spaces 60,62, defined between the first and second
refining members 20,
and the third and fourth refining members 40, 50 (see also FIGS. 8 and 9). In
other
embodiments (not shown), control of the size of the gaps may be achieved by
one or more magnetic
30
bearings. Magnetic bearings that
control the axial position of the shaft 72 may be used to control
the position of the rotating rotor members that are fixed to the shaft 72.
Magnetic bearings may
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be used to control the axial position of one or more additional movable
sections of the main support
frame, i.e., the movable support frame 68, to which one or more of the non-
rotating stator members
are attached.
As will be discussed further herein, a slurry of wood pulp comprising wood
fibers passes
through the refining spaces 60, 62. As the jack screw rotates in a first
direction, it causes
movement of the movable support frame 68 and the fourth refining member 50
inwardly towards
the third refining member 40. The fourth refining member 50 then applies an
axial force to the
pulp slurry passing through the second refining space 62 which, in turn,
applies an axial force to
the third refining member 40, causing the third refining member 40, the
support 70 and the second
refining member 30 to move inwardly toward the first refining member 20. As
the jack screw
rotates in a second direction, opposite to the first direction, it causes
movement of the movable
support frame 68 and the fourth refining member 50 outwardly away from the
third refining
member 40. This reduces the axial force applied by the fourth refining member
50 to the pulp
slurry passing through the second refining space 62 which, in turn, reduces an
axial force applied
by the pulp slurry to the third refining member 40. The axial force applied by
the pulp slurry
passing through the first refining space 60 is then sufficient to cause the
second refining member
30, the support 70 and the third refining member 40 to move toward the fourth
refining member
50. This occurs until the axial forces applied by the wood slurries passing
through the first and
second refining spaces 60, 62 against the second and third refining members 30
and 40 are
approximately equal.
In some embodiments (not shown), the disc refiner 10 may further comprise a
further motor
and a second rotatable shaft, and the first and/or fourth refining members 20,
50 may be coupled
to the second rotatable shaft such that the first and/or fourth refining
members 20, 50 may be
counter-rotatable relative to the second and/or third refining members 30, 40,
respectively_ In
other embodiments (not shown), the disc refiner 10 may comprise only one pair
of refining
members in which one refining member is a non-rotating stator member and the
other refining
member is a rotating rotor member. In further embodiments (not shown), the
disc refiner may
comprise three or more pairs of refining members. In yet further embodiments
(not shown), the
disc refiner 10 may comprise a conical refiner with one or more pairs of
refining members.
FIGS. 2 and 3 are plan views of the refining surfaces 24, 34 of the first
refining body 22
and the second refining body 32, respectively, for use in a pulp refiner
according to one
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embodiment of the present disclosure_ Although not discussed in detail herein,
the structure of the
refining surfaces 44, 54 of the third and fourth refining bodies 42, 52,
respectively, (see FIG. 1)
may be substantially similar to the refining surfaces 24, 34 of the first and
second refining bodies
22, 32, respectively.
With reference to FIGS. 1 and 2, the first refining body 22 may comprise a
plurality of
sections, e.g. sections 22A-22C, that are bolted or otherwise attached
together to form the disc-
shaped refining body 22 comprising a radially outer edge 27. The refining
surface 24 comprises a
plurality of elongated refiner bars 26 separated from one another by refiner
grooves 28. Although
not shown in FIG. 2, it is understood that the other sections (not labeled) of
the first refining body
22 would similarly comprise refiner bars 26 and refiner grooves 28. The
refiner bars 26 extend
radially outwardly from a radially inner location 23 toward the radially outer
edge 27 of the first
refining body 22. The refiner bars 26 may be slanted at various angles as
shown in FIG. 2, and
each section 22A-22C may comprise one or more segments (not separately
labeled) of refiner bars
26 that are slanted in different directions_ The refiner bars 26 and refiner
grooves 28 within each
section 22A-22C in FIG. 2 may otherwise be similar in structure.
As shown in FIG 3, the second refining body 32 may similarly comprise a
plurality of
sections, e.g. sections 32A-32C, that are bolted or otherwise attached
together to form the disc-
shaped refining body 32 comprising a radially outer edge 37. The refining
surface 34 comprises a
plurality of elongated refiner bars 36 separated from one another by refiner
grooves 38. Although
not shown in FIG. 3, it is understood that the other sections (not labeled) of
the second refining
body 32 would similarly comprise refiner bars 36 and refiner grooves 38. The
refiner bars 36
extend radially outwardly from a radially inner location 33 toward the
radially outer edge 37 of
the second refining body 32. The refiner bars 36 may be slanted at various
angles as shown in
FIG. 3, and each section 32A-32C may comprise two or more segments (not
separately labeled)
of refiner bars 36 that are slanted in different directions. The refiner bars
36 and refiner grooves
38 within each section 32A-32C in FIG 3 may otherwise be similar in structure.
Paths of a slurry of wood pulp comprising wood fibers through the refiner 10
are illustrated
via arrows B in FIG. 1. With reference to FIGS. 1-3, the pulp slurry enters
the disc refiner 10
through an inlet 16 and passes into the refiner inner cavity 64 via a central
aperture 21 in the first
refining member 20. The refiner inner cavity 64 may be defined, in part, by
the fixed support
frame 66 and the movable support frame 68. The refining surfaces 24, 34 may
comprise one or
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more additional rows of refiner bars (not labeled), such as those located near
the center of the
refining bodies 22, 32, e.g., near the central aperture 21. These additional
refiner bars may be
wider and spaced further apart than the other refiner bars 26 to break up
large fiber bundles before
they enter the refining space 60. The wood fibers travel radially outwardly
between the refining
members 20, 30, 40, 50. The first refining space 60 defined between the first
and second refining
members 20, 30 and the second refining space 62 defined between the third and
fourth refining
members 40, 50 define separate paths along which the wood fibers may travel
from the inlet 16 to
the outlet 18. It is believed that the wood fibers only pass through one of
the first and second
refining spaces 60, 62 at a time. The refiner grooves 28, 38 may be considered
part of the refining
space 60 defined between the first and second refining members 20, 30. It is
believed that a
majority of the flow of the wood fibers through the refining space 60 passes
through the refiner
grooves 28, 38. Similarly, the refiner grooves (not shown) of the third and
fourth refining members
40,50 may be considered part of the refining space 62 defined between the
third and fourth refining
members 40,50. It is believed that a majority of the flow of wood fibers
through the refining space
62 passes through the refiner grooves (not labeled) of the third and fourth
refining members 40,
50. After processing, the wood fibers exit the refiner 10 via the outlet 18,
at least in part under the
action of centrifugal force.
FIGS. 4A and 4B are detailed views of one portion of the refining surface 24
of the first
refining body 22, and FIGS. 5A and 5B are detailed views of a corresponding
portion of the
refining surface 34 of the second refining body 32. FIGS. 6A and 6B are
partial cross-sectional
views of the refining bodies 22, 32 taken along lines 6A-6A and 6B-6B,
respectively,
illustrating two embodiments of a refiner bar 26, 36, as shown in FIGS. 4A,
4B, 5A, and 5B. FIG.
7 is a partial cross-sectional view taken along line 7-7 in FIGS. 4A, 413, 5A,
and 5B.
In the embodiments shown in FIGS. 44, 5A, 6A, and 7, each refiner bar 26, 36
may
comprise a first refiner bar 26A, 36A and a second refiner bar 26B, 36B. The
first refiner bars
26A, 36A may be separated from one another by first refiner grooves 28A, 38A,
and the second
refiner bars 26B, 36B may be separated from one another by second refiner
grooves 28B, 38B.
The first and second refiner grooves 28A, 38A, 28B, 38B may have a width WG of
from about 2.0
mm to about 6.0 mm. This range includes all values and subranges therebetween,
including, for
example, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, and 6.0 mm. As shown in FIGS.
6A and 7, the first
refiner bars 26A, 36A comprise a first maximum height Hi extending upward from
a floor Ft of
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the adjacent first refiner groove 28A, 38A, and the second refiner bars 26B,
369 comprise a second
maximum height H2 extending upward from a floor F2 of the adjacent second
refiner groove 28B,
38B, in which the second maximum height H2 is less than the first maximum
height Hi. The
minimum height difference between Hi and I-b is depicted as Di in FIG. 6A. In
some examples,
a radially outer portion ROL of the first refiner bar 26A, 36A may comprise a
step-down from the
first maximum height Hi to the second maximum height H2.
In some examples, the second maximum height H2 may be at least about 0.35 min
(th 0.05
mm) less than the first maximum height Hi. In other examples, the second
maximum height 112
may be at least 0.7 mm ( 0.05 mm) less than the first maximum height Hi. In
further examples,
the first maximum height Hi of the first refiner bars 26A, 36A, when measured
from the floor Fi
of the adjacent first refiner groove 28A, 38A, may be from about 4.0 mm to
about 10,0 mm (th 0.5
mm). This range includes all values and subranges therebetween, including, for
example, 4.0, 4.5,
5.0, 5.5, 6.0, 6.5, 7.0, 7.5, 8.0, 8.5, 9.0, 9.5, and 10.0 mm. In a particular
example, the second
maximum height H2 of the second refiner bars 269, 36B, when measured from the
floor F2 of the
adjacent second refiner groove 28B, 38B, may be from about 0.35 mm to about
1.5 mm (th 0.05
mm) less than the first maximum height Hi. This range includes all values and
subranges
therebetween, including, for example, 035, 0.4, 0.45, 0.5, 0.55, 0.6,
0.65,0.7, 0.75, 0.8, 0.85, 0.9,
0.95,1.0, 1.05, 1,1, 1.15, 1.2, 125, 13, 135, 1.4, 1,45, and 1.5 min. In
another particular example,
the second maximum height H2 of the second refiner bars 26B, 36B, when
measured from the floor
F2 of the adjacent second refiner groove 28B, 38B, may be from about 0.7 mm to
about 1.5 mm
(+ 0.05 mm) less than the first maximum height Hi. This range includes all
values and subranges
therebetween, including, for example, 0.7, 0.75, 0.8, 0.85, 0.9, 0.95, 1.0,
1.05, 1,1, 1,15, 1.2, 1.25,
1.3, 1.35, 1.4, 1.45, and 1.5 min. In yet further examples in which the
radially outer portion ROI
of the first refiner bars 26A, 36A comprises a step-down from the first
maximum height Hi to the
second maximum height It, the second maximum height 112 may be at least about
1.5 mm 0.05
mm) less than the first maximum height Hi. In some instances, the second
maximum height H2
may be at least about 2.0 mm ( 0.05 mm) less than the first maximum height
Hi, and in other
instances, the second maximum height H2 may be at least about 3.0 mm (+ 0.05
mm) less than the
first maximum height Hi.
Each of the first refiner bars 26A, 36A extend from a radially inward position
Pi on the
refining surface 24, 34 to a first radially outward position P2 on the
refining surface 24, 34_ Each
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of the second refiner bars 26B, 36B extend to a second radially outward
position P3 on the refining
surface 24, 34. The second radially outward position P3 may be nearer to an
outermost pan, e.g.,
the radially outer edge 27, 37, of the refining body 22, 32 than the first
radially outward position
P2. In some examples, the radially inward position Pi may comprise a position
at or near the
radially inner location 23, 33. The second refiner bars 26B, 36B may comprise
a longitudinal
length Li from about 0.6 cm to about 10 cm and preferably from about 2 cm to
about 10 cm. The
first refiner bars 26A, 36A and the second refiner bars 26B, 36B may comprise
a width W26
extending between sides edges of the respective refiner bars 26A, 36A, 26B,
36B of from about
2.0 mm to about 8.0 mm. This range includes all values and subranges
therebetween, including,
for example, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, and
8.0 mm.
In some embodiments, the second refiner bars 26B, 36B may be integral with the
first
refiner bars 26A, 36A, as shown in FIGS. 4A, 5A, and 6A, such that the second
refiner bars 26B,
36B extend from the first radially outward position P2 to the second radially
outward position P3.
In a particular embodiment, the second refiner bars 26B, 36B may slope
continuously downward
from the first radially outward position P2 to the second radially outward
position P3. As shown
in FIG. 6A, the height of the second refiner bars 2614, 3614 may decrease
continuously along
substantially the entire longitudinal length Li from the second maximum height
112 to a second
minimum height Hr. In another particular embodiment, the second refiner bars
26B, 36B may
extend substantially horizontally from the first radially outward position P2
to the second radially
outward position P3, as depicted by the dashed line in FIG. 6A, such that the
second refiner bars
268, 36B are at the second maximum height H2 along substantially the entire
longitudinal length
Li of the second refiner bars 26B, 36B. In other embodiments (not shown), the
first refiner bars
26A, 36A may be radially separated from the second refiner bars 2614, 3614 by
a space.
With reference to FIGS. 4A, 5A, and 7, the refining surfaces 24, 34 may
comprise dams
29, 39 provided in at least a portion of the first refiner grooves 28A, 38A.
The dams 29, 39 may
comprise a height that is substantially the same as or less than the height of
the adjacent first refiner
bars 26A, 36A. The dams 29, 39 serve to divert wood fibers from the first
refiner grooves 28A,
38A so as to be engaged by the first and second refiner bars 26A, 36A, 26B,
36B.
With reference to FIGS. 1, 4A, 5A, and 6A, when a slurry of wood pulp
comprising wood
fibers is supplied to the frame 66, e.g., the inlet 16, of the refiner 10, the
first refiner bars 26A,
36A are adapted to refine the wood fibers in the pulp slurry, while the second
refiner bars 26B,
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36B are adapted to break up or separate fiber bundles. Refining may be used to
break apart and
reduce small flocs of fibers, induce external or internal fibrillation to
effect fiber bonding, and/or
cut a significant number of long wood fibers in the wood pulp slurry such that
the lengths of the
long wood fibers are reduced. However, the refining process also causes some
of the wood fibers
to re-form into small, dense fiber bundles ("flakes"), particularly during
refining of long fibers
such as softwood. The fiber bundles may adversely affect tensile strength,
formation, etc. of the
finished paper product, seed formation of strings of pulp that clog downstream
components, and/or
inhibit the drainage of fluid/water from the fibers during paper product
production. Thus, the
flakes should be broken apart after refining in a process called deflaking. As
used herein, the term
"deflaking" is used to refer to the process of breaking apart fiber bundles
that have formed during
refining. When refining involves a conventional pulp refiner, deflaking
typically takes place in
one or more subsequent refiners, frequently operating at low power and
referred to as a "tickler"
refiner, or deflakers. Use of separate refiner(s) or deflakers increases the
cost and complexity of
the system. In addition, the tickler refiner(s) and the associated lines and
tank(s) and a downstream
machine chest may accumulate residual amounts of fibers from previous runs and
allow the
continued formation of fiber bundles. Processing in the tickler refiner(s) may
degrade the
properties of the fibers when dissimilar pulp slurries are refined together.
It is believed that
refining members 20, 30, 40, 50 according to the present disclosure solve
these problems by
incorporating refiner bars 26A, 26B, 36A, 36B of differing heights such that
refining and deflaking
may be performed within a single refiner 10.
The first maximum height Hi of the first refiner bars 26A, 36A, which is
greater than the
second maximum height H2, means that the wood fibers are subjected to high
intensity shearing
and compression forces as the fibers pass through the portion of the refining
space 60 that is at
least partially defined by the first refiner grooves 28A, 38A and engaged by
cutting side edges
126A, 136A of the first refiner bars 26A, 36A on the opposing first and second
refining surfaces
24, 34 (see also FIGS 8 and 9). Hence, the portion of the refining space 60
that is at least partially
defined by the first refiner grooves 28A, 38A and extends from the radially
inward position Pi on
the refining surface 24, 34 to the first radially outward position P2 on the
refining surface 24, 34
may at least partially define a refining zone. In some examples, the radially
inner location 23, 33
of the respective refining body 22, 32 may define the start of the refining
zone. When the refined
fibers pass into the portion of the refining space 60 that is at least
partially defined by the second
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refiner grooves 28B, 3813 (e.g., from about the first radially outward
position P2 to about the second
radially outward position P3 in FIG. 6A), the second refiner bars 26B, 36B
comprise the second
maximum height I-I2, and the intensity of the force applied to the fibers
decreases in response to
the reduced height (see also FIGS. 8 and 9). Thus, the portion of the refining
space 60 that is at
least partially defined by the second refiner grooves 28B, 38B and extends
from the first radially
outward position P2 to the second radially outward position P3 on the refining
surface 24, 34 may
at least partially define a deflaking zone. The decreased force applied to the
fibers in the deflaking
zone is believed to break up the fiber bundles formed during refining without
further refining or
only minimally refining the fibers. In the embodiment depicted in FIG. 6A, the
second refiner
bars 268, 36B form an annular ring defining the deflaking zone around a
radially outer portion
(not separately labeled) of the first and second refining bodies 22, 32. It is
believed that the second
maximum height H2 of the second refiner bars 26B, 36B should be at least about
0.35 mm ( 0.05
mm) less than the first maximum height Hi of the first refiner bars 26A, 36A
in order to cease
refining of the fibers and begin deflaking. The refining zone may comprise 60%
or more of the
total area defined by both the refining and deflaking zones on each refining
surface 24, 34.
In the embodiments shown in FIGS. 413, 58, and 68, each refiner bar 26', 36'
may
comprise a first refiner bar 26K, 36A', a second refiner bar 268', 3611', a
third refiner bar 26C,
36C, and a fourth refiner bar 26D, 36D. The first refiner bars 26A', 36A' and
the second refiner
bars 26B', 36' may be substantially similar to the first refiner bars 26A, 36A
and the second refiner
bars 268, 368 as depicted in FIGS. 4A, 5A, 6A, and 7 and as described herein
but the first and
second refiner bars 26A', 36A', 26B', 36B' may extend radially outwardly a
shorter distance. The
first refiner bars 26K, 36A' may be separated from one another by first
refiner grooves 28A',
38A', and the second refiner bars 2611', 3611' may be separated from one
another by second refiner
grooves 2813', 3813'. The first and second refiner grooves 28A', 38A', 28B',
3813' may have a
width WG of from about 2.0 mm to about 6.0 mm. This range includes all values
and subranges
therebetween, including, for example, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5,
and 6.0 mm. The third
refiner bars 26C, 36C may be separated from one another by third refiner
grooves 28C, 38C, and
the fourth refiner bars 26D, 36D may be separated from one another by fourth
refiner grooves 281),
38D. As shown in FIG. 6B, the third refiner bars 26C, 36C comprise a third
maximum height H3
extending upward from a floor F3 of the adjacent third refiner groove 28C,
38C, and the fourth
refiner bars 26D, 36D comprise a fourth maximum height 114 extending upward
from a floor F4 of
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the adjacent fourth refiner groove 28D, 38D, in which the fourth maximum
height 114 is less than
the third maximum height H3. The third maximum height H3 may substantially
equal the first
maximum height Hi' and the fourth maximum height fla may substantially equal
the second
maximum height H2. The minimum height difference between I-13 and H4 is
depicted as D2 in FIG.
6B. In some examples, a radially outer portion R02 of the third refiner bar
26C, 36C may comprise
a step-down from the third maximum height 143 to the fourth maximum height Hi.
The third and
fourth refiner grooves 28C, 38C, 28D, 38D may have a width WG of from about 2M
mm to about
6.0 mm. This range includes all values and subranges therebetween, including,
for example, 2.0,
2.5, 3.0, 3.5, 4.0,4+5, 5.0, 5.5, and 6.0 mm.
In some examples, the fourth maximum height 1-14 may be at least 0.35 mm (
0.05 mm)
less than the third maximum height H3 In other examples, the fourth maximum
height H4 may be
at least 0.7 mm (" 0.05 mm) less than the third maximum height H3. In further
examples, the third
maximum height H3 of the third refiner bars 26C, 36C, when measured from the
floor F3 of the
adjacent third refiner groove 28C, 38C, may be from about 4.0 mm to about 10.0
mm (+ 0.5 mm).
This range includes all values and subranges therebetween, including, for
example, 4.0, 4.5, 5.0,
5.5, 6+0,6.5, 7.0, 7.5, 8.0, 8.5, 9+0,9.5, and 10.0 min. In a particular
example, the fourth maximum
height 114 of the fourth refiner bars 26D, 36D, when measured from the floor
F4 of the adjacent
fourth refiner groove 28D, 38D, may be from about 0.35 mm to about 1.5 mm (
0.05 mm) less
than the third maximum height 1-13. This range includes all values and
subranges therebetween,
including, for example, 0.35, 0.4, 0.45, 0.5, 0.55, 0.6, 0.65, 0.7, 035, 0.8,
0.85, 0.9, 0.95, 1.0, 1.05,
1.1, 1.15, 1.2, 1.25, 1.3, 1.35, 1.4, 1.45, and 1,5 mm. In another particular
example, the fourth
maximum height H4 of the fourth refiner bars 26D, 36D, when measured from the
floor F4 of the
adjacent fourth refiner groove 28D, 38D, may be from about 0.7 mm to about 1.5
min ( 0.05 mm)
less than the third maximum height H3. This range includes all values and
subranges therebetween,
including, for example, 0_7, 0.75, 0.8, 0.85, 0.9, 0.95, 1.0, 1.05, 1.1, 1.15,
1.2, 1.25, 1.3, 1.35, 1.4,
1.45, and 1.5 mm. In yet further examples in which the radially outer portion
R02 of the third
refiner bars 26C, 36C comprises a step-down from the third maximum height H3
to the fourth
maximum height H4, the fourth maximum height H4 may be at least about 1,5 mm
(+ 0.05 mm)
less than the third maximum height 113. In some instances, the fourth maximum
height H4 may be
at least about 2.0 mm ( 0.05 mm) less than the third maximum height 1-13, and
in other instances,
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the fourth maximum height 114 may be at least about 3.0 mm ( 0.05 mm) less
than the third
maximum height H3.
Each of the first refiner bars 26A', 36A' extends from a radially inward
position Pr on the
refining surface 24, 34 to a first radially outward position P2' on the
refining surface 24, 34. Each
of the second refiner bars 26B', 36W extends to a second radially outward
position P3' on the
refining surface 24, 34. Each of the third refiner bars 26C, 36C extend to a
third radially outward
position P4 on the refining surface 24, 34. Each of the fourth refiner bars
26D, 36D extend to a
fourth radially outward position Ps on the refining surface 24, 34. The fourth
radially outward
position Ps may be nearer to an outermost part, e.g., the radially outer edge
27, 37, of the refining
body 22, 32 than the first, second, and third radially outward positions P2',
P3' and Pa. The fourth
refiner bars 26D, 36D may comprise a longitudinal length L2 from about 0.6 cm
to about 10 cm
and preferably from about 2 cm to about 10 cm. The third refiner bars 26C, 36C
and the fourth
refiner bars 26D, 36D may comprise a width (not separately labeled) extending
between sides
edges of the respective refiner bars 26C, 36C, 26D, 36D of from about 2.0 mm
to about 8.0 mm.
This range includes all values and subranges therebetween, including, for
example, 2.0, 2.5, 3.0,
3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, and 8.0 mm.
In some embodiments, the second refiner bars 268', 36B' may be integral with
the first
refiner bars 26A', 36A', as shown in FIGS. 4B, 5B, and 6B, such that the
second refiner bars 26W,
36B' extend from the first radially outward position P2' to the second
radially outward position Pr.
In some embodiments, as shown in FIGS. 4B, 5B, and 6B, the third refiner bars
26C, 36C may be
integral with the second refiner bars 26B', 36B' such that the third refiner
bars 26C, 36C extend
from the second radially outward position P3' to the third radially outward
position P4' and the
fourth refiner bars 26D, 36D may be integral with the third refiner bars 26C,
36C such that the
fourth refiner bars 26D, 3613 extend from the third radially outward position
114 to the fourth
radially outward position Ps. In a particular embodiment, the second refiner
bars 26B', 368' may
slope continuously downward from the first radially outward position Pr to the
second radially
outward position P3'. As shown in FIG. 6B, the second refiner bars 26W, 36W
may comprise a
longitudinal length Li of from about 0.6 cm to about 10 cm and preferably from
about 2 cm to
about 10 cm. The height of the second refiner bars 26B', 368' may decrease
continuously along
substantially the entire longitudinal length Li from the second maximum height
142 to a second
minimum height Hr. In another particular embodiment, the second refiner bars
268', 36B' may
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extend substantially horizontally from the first radially outward position P2'
to the second radially
outward position P3', as depicted by the dashed line in FIG. 68, such that the
second refiner bars
268', 368' are at the second maximum height H2 along substantially the entire
longitudinal length
Li of the second refiner bars 268', 368'. In a particular embodiment, the
fourth refiner bars 26D,
360 may slope continuously downward from the third radially outward position
P4 to the fourth
radially outward position Ps. As shown in FIG. 6B, the height of the fourth
refiner bars 26D, 36D
may decrease continuously along substantially the entire longitudinal length
L2 from the fourth
maximum height 114 to a fourth minimum height 114'. In another particular
embodiment, the fourth
refiner bars 26D, 36D may extend substantially horizontally from the third
radially outward
position P4 to the fourth radially outward position Ps, as depicted by the
dashed line in FIG. 6B,
such that the fourth refiner bars 26D, 360 are at the fourth maximum height
FI4 along substantially
the entire longitudinal length L2 of the fourth refiner bars 26D, 36D. In
other embodiments (not
shown), the third refiner bars 26C, 36C may be radially separated from the
fourth refiner bars 26D,
36D by a space.
With reference to FIGS. 4B, 5B, and 7, the refining surface 24, 34 may
comprise dams 29,
39 provided in at least a portion of the first and/or third refiner grooves
28A', 38A', 28C, 38C, as
described herein.
The first refiner bars 26A', 36A' in FIGS. 4B, 5B, and 6B are adapted to
refine wood fibers,
and the second refiner bars 26B', 36B' in FIGS. 4B, 5B, and 6B are adapted to
break up fiber
bundles, as described with respect to the first and second refiner bars 26A,
36A, 26B, 368 in FIGS,
4A, 5A, and 6A. The third refiner bars 26C, 36C are adapted to refine wood
fibers (similar to the
first refiner bars 26A', 36A'), while the fourth refiner bars 26D, 36D are
adapted to break up fiber
bundles (similar to the second refiner bars 26B', 36B'), as described herein.
With reference to FIGS. 1, 4B, 5B, and 6B, the portions of the refining space
60 that are at
least partially defined by the first refiner grooves 28A', 38A' and the third
refiner grooves 28C,
38C and extending from the radially inward position Pr to the first radially
outward position Pr
and from the second radially outward position Pr to the third radially outward
position P4 on the
refining surface 24, 34 may at least partially define first and second
refining zones, respectively,
as described herein. The portions of the refining space 60 that are at least
partially defined by the
second refiner grooves 28B', 38B' and the fourth refiner grooves 28D, 38D and
extending from
the first radially outward position Pr to the second radially outward position
Pr and from the third
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radially outward position P4 to the fourth radially outward position P5 on the
refining surface 24,
34 may at least partially define first and second deflaking zones,
respectively, as described herein.
It is believed that the second maximum height H2 of the second refiner bars
26B', 36B' should be
at least about 0.35 mm (th 0.05 mm) less than the first maximum height Hi of
the first refiner bars
26K, 36K in order to cease refining of the fibers and begin deflaking.
Similarly, it is believed
that the fourth maximum height 114 of the fourth refiner bars 26D, 36D should
be at least about
0.35 mm (th 0.05 mm) less than the third maximum height H3 of the third
refiner bars 26C, 36C in
order to cease refining of the fibers and begin deflaking. The first and
second refining zones may
comprise 60% or more of the total area defined by both the first and second
refining and deflaking
zones on each refining surface 24, 34.
FIGS. 8 and 9 are partial cross-sectional views of the first and second
refining bodies 22,
32/132 of the first and second refining members 20, 30/130 according to the
present disclosure.
The first refining member 20 is spaced apart and positioned adjacent to and
across from the second
refining member 30 (see FIG. 1). In the embodiment shown in FIG. 8, a refining
body according
to the present invention, e.g., the first refining body 22, is paired with the
conventional refining
body 132. The first refining body 22 comprises a first refiner bar 26A, a
first refiner groove 28A,
a second refiner bar 2611, and a second refiner groove 28B, which may
correspond to the first and
second refiner bars 26A, 26B and first and second refiner grooves 28A, 28B, as
described herein
with respect to FIGS. 4A, 4B, 6A, 6B, and 7. It is understood that the
features described in FIG.
8 with respect to the first and second refiner bars 26A, 26B and first and
second refiner grooves
28A, 28B apply equally to the third and fourth refiner bars 26C, 26D and third
and fourth refiner
grooves 28C, 28D, respectively, as described herein (see FIGS, 4B, 5B, and
6B). The conventional
refining body 132 comprises a conventional refiner bar 136, which is a uniform
height along
substantially the entire longitudinal length of the refiner bar 136, and a
refiner groove 138. In
other embodiments (not shown), the non-rotating stator member, e.g., the first
refining member
20, may comprise conventional refiner bars that are a uniform height along
substantially their
entire length, and the rotating rotor member, e.g., the second refining member
30 may comprise
refiner bars 26A, 26B and refiner grooves 28A, 28B according to the present
disclosure (see FIG.
1).
A first gap Gi is defined in FIG. 8 between an outer surface S26A of the first
refiner bar 26A
and an outer surface S136 of the conventional refiner bar 136. In examples in
which the second
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refiner bar 26B slopes continuously downward, a second gap G2 may be defined
between an outer
surface S26B of the second refiner bar 26B and the outer surface of the
conventional refiner bar
136, in which G2 is greater than Gi. In examples in which the second refiner
bar 26B extends
substantially horizontally (shown in FIG 8 by dashed lines), a third gap G3
may be defined
between an outer surface S26B' of the second refiner bar 26B and the outer
surface S136 of the
conventional refiner bar 136, in which G3 is greater than Gi. As shown in FIG.
8, in embodiments
in which one of the second refiner bars, e.g., the second refiner bar 26B, is
sloped, a distance
between the outer surface S26B of the second refiner bar 26B and the outer
surface S136 of the
conventional refiner bar 136 may increase continuously along at least a
portion of the longitudinal
length (not labeled; see FIGS. 6A and 6B) of the second refiner bar 26B from a
minimum distance
corresponding to the third gap G3 to a maximum distance corresponding to the
second gap G2.
In the embodiment shown in FIG. 9, one refining body according to the present
invention,
e.g., the first refining body 22, is paired with another refining body
according to the present
invention, e.g., the second refining body 32. The first refining body 22
comprises a first refiner
bar 26A, a first refiner groove 28A, a second refiner bar 26B, and a second
refiner groove 28B,
which may correspond to the first and second refiner bars 26A, 268 and first
and second refiner
grooves 28A, 288, as described herein with respect to FIGS. 4A, 48, 6A, 68,
and 7. The second
refining body 32 comprises a first refiner bar 36A, a first refiner groove
38A, a second refiner bar
36B, and a second refiner groove 38B, which may correspond to the first and
second refiner bars
36A, 36B and first and second refiner grooves 38A, 38B, as described herein
with respect to FIGS.
5A, 5B, 6A, 6B, and 7. It is understood that the features described in FIG. 9
with respect to the
first and second refiner bars 26A, 26B, 36A, 36B and first and second refiner
grooves 28A, 28B,
38A, 388 apply equally to the third and fourth refiner bars 26C, 26D and third
and fourth refiner
grooves 28C, 28D, respectively, as described herein (see FIGS. 411, 511, and
68).
A first gap GI is defined between an outer surface S26A of the first refiner
bar 26A of the
first refining body 22 and an outer surface S36A of the first refiner bar 36A
of the second refining
body 32. In examples in which the second refiner bar 26B of the first refining
body 22 and the
second refiner bar 36B of the second refining body 32 both slope continuously
downward, a gap
G4 may be defined between an outer surface S26B of the second refiner bar 26B
and an outer surface
S36B of the second refiner bar 36B of the second refining body 32, in which G4
is greater than Gr.
In examples in which one of the second refiner bars, e.g., the second refiner
bar 2611 of the first
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refining body 22, slopes continuously downward and the other of the second
refiner bars, e.g., the
second refiner bar 36B of the second refining body 32, extends substantially
horizontally (shown
in FIG. 9 by dashed lines), a gap Gs may be defined between the outer surface
S26B of the second
refiner bar 26B and an outer surface 53613' of the second refiner bar 36B, in
which G5 is greater
than Gi. In examples in which the second refiner bar 26B of the first refining
body 22 and the
second refiner bar 36B of the second refining body 32 both extend
substantially horizontally
(shown in FIG. 9 with dashed lines), a gap Gs may be defined between an outer
surface SzsEr of
the second refiner bar 26B and the outer surface S368' of the second refiner
bar 36B, in which Gs
is greater than Gi. In some particular examples, G4 is greater than Gs, and Gs
is greater than G6.
As shown in FIG. 9, in embodiments in which one or both of the second refiner
bars 26B,
36B are sloped, a distance between the outer surfaces S26B, S26B', S36B, S36B'
of the second refiner
bars 26B, 36B may increase continuously along at least a portion of the
longitudinal length (not
labeled; see FIGS. 6A and 6B) of one or both of the respective second refiner
bars 26B, 36B. For
example, when one refining body, e.g., the first refining body 22, comprises a
sloped second refiner
bar 26B, the distance between the outer surfaces S26B, S36B' of the second
refiner bars 26B, 36B
may increase from a minimum distance corresponding to the gap G6 to a maximum
distance
corresponding to the third gap Gs. When both refining bodies 22, 32 comprise
sloped second
refiner bars 26B, 36B, the distance between the outer surfaces S26B, S36B of
the second refiner bars
26B, 36B may increase from a minimum distance corresponding to the gap G6 to a
maximum
distance corresponding to the second gap G4.
In all embodiments depicted in FIGS. 8 and 9, as the rotatable refining member
(e.g., the
first refining member 20; see FIG. 1) rotates relative to the stationary
refining member (e.g., the
second refining member 30/130; see FIG, I), the pulp slurry comprising wood
fibers is supplied
to the frame 66, e.g., the inlet 16, of the refiner 10 (see FIG. 1) and enters
the refining space 60
defined between the first and second refining bodies 22, 32/132. With
reference to FIG. 8, as the
wood fibers enter the portion of the refining space 60 that is at least
partially defined by the first
refiner grooves 28A of the first refining body 22 and the refiner grooves 138
of the second refining
body 132, the first and second refining bodies 22, 132 are spaced apart to
define the first gap Gi
between the first refiner bars 26A of the first refining body 22 and the
conventional refiner bars
136 of the second refining body 132 such that the refiner bars 26A and 136
interact with one
another to refine the wood fibers, as described herein. It is believed that
the first gap Gi should be
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less than about 0.9 mm 0.05 min) and preferably from about 0.2 mm to about 0.9
mm ( 0.05
mm) in order for refining to occur. This range includes all values and
subranges therebetween,
including, for example, 0.2, 0.25, 0.3, 0.35, 0.4, 0.45, 0.5, 0.55, 0.6, 0.65,
0.7, 0.75, 0.8, 0.85, and
0.9 mm. In some examples, the first gap Gi may be from about 0.1 mm to about
0.5 mm 0.05
um). This range includes all values and subranges therebetween, including, for
example, 0.1,
0.15, 0.2, 0.25, 0.3, 0.35, 0.4, 0.45, and 0.5 mm.
With continued reference to FIG. 8, as the wood fibers pass into the portion
of the refining
space 60 that is at least partially defined by the second refiner grooves 28B
of the first refining
body 22 and the refiner grooves 138 of the second refining body 132, a
distance between the second
refiner bars 26B of the first refining body 22 and the refiner bars 136 of the
second refining body
132 is increased such that it is believed that refining stops and deflaking
begins. In embodiments
in which the second refiner bars 26B slope continuously downward, the distance
increases from
the first gap GI to the second gap G2. In embodiments in which the second
refiner bars 26B extend
substantially horizontally, the distance increases from the first gap GE to
the third gap Ca It is
believed that the distance between the second refiner bars 26B of the first
refining body 22 and the
refiner bars 136 of the second refining body 132, i.e., G2 or G3, should be
from about 0,9 mm to
about 1.5 mm ( 0.05 mm) in order for deflaking to occur. This range includes
all values and
subranges therebetween, including, for example, 0.9, 0.95, 1,0, 1,05, 1,1,
1,15, 1,2, 1,25, 1,3, 1,35,
1A, 1.45, and 1.5 mm.
With reference to FIG. 9, as the wood fibers enter the portion of the refining
space 60 that
is at least partially defined by the first refiner grooves 28A, 38A of the
first and second refining
bodies 22, 32, respectively, the first and second refining bodies 22, 32 are
spaced apart to define
the first gap GI between the first refiner bars 26A, 36A such that the refiner
bars 26A, 36A interact
with one another to refine the wood fibers, as described herein. As the wood
fibers pass into the
portion of the refining space 60 that is at least partially defined by the
second refiner grooves 28B,
388 of the first and second refining bodies 22, 32, respectively, a distance
between the second
refiner bars 26B of the first refining body 22 and the second refiner bars 36B
of the second refining
body 32 increases to one of the gaps G4, Gs, or G6 such that refining stops
and deflaking begins.
It is believed that the first gap GI should be less than about 0.9 mm (+ 0.05
mm) and preferably
from about 0.2 mm to about 0.9 mm ( 0.05 mm) in order for refining to occur.
This range includes
all values and subranges therebetween, including, for example, 0.2, 0.25, 0.3,
0.35, 0.4, 0.45, 0.5,
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0.55, 0.6, 0.65, 0.7, 0.75, 0.8, 0.85, and 0.9 mm. In some examples, the first
gap GI may be from
about 0.1 mm to about 0.5 mm ( 0.05 mm). This range includes all values and
subranges
therebetween, including, for example, 0.1, 0.15, 0.2, 0.25, 0.3, 0.35, 0.4,
0.45, and 0.5 mm. It is
also believed that the gaps G4, G5 G6 should be from about 0.9 mm to about 1.5
mm ( 0.05 mm)
in order for deflaking to occur. This range includes all values and subranges
therebetween,
including, for example, 0.9, 0.95, 1.0, 1.05, 1.1, 1.15, 1.2, 1.25, 1.3, 1.35,
1.4, 1.45, and 1.5 mm
for the range of about 0.9 mm to about 1.5 mm.
With reference to FIGS. 1, 6A, 6B, 8, and 9, the gaps GI and G2, G3, G4, G4,
G5, G6 defined
between the refining bodies 22, 32/132 may be adjusted by applying axial
pressure to at least one
of the first or second refining members 20,30, for example, via the second
motor 76 that is coupled
to the movable support frame 68 via the jack screw (not shown). For a single-
disc refiner, the
second refining member 30 may be coupled directly to the movable support frame
68 such that the
second refining member 30 moves with the movable support frame 68 as the
latter is moved via
the second motor 76 and the jack screw. For a double-disc refiner 10, the
second refining member
30 is moved as described above, i.e., as the jack screw rotates in a first
direction, it causes
movement of the movable support frame 68 and the fourth refining member 50
inwardly towards
the third refining member 40_ The fourth refining member 50 then applies an
axial force to the
wood slurry passing through the second refining space 62 which, in turn,
applies an axial force to
the third refining member 40, causing the third refining member 40, the
support 70 and the second
refining member 30 to move inwardly toward the first refining member 20.
The gap Gi defined between the refiner bars 26A, 36A, 136 may be maintained at
a
substantially constant gap value by adjusting the positioning of the second
refining member 30
relative to the first refining member 20 via the second motor 76 (controlled
manually or via a
controller/processor coupled to the second motor 76) and jack screw so that an
amount of power
required to be input/generated by the first motor 74 (controlled manually or
via a
controller/processor coupled to the first motor 74), running at a
predetermined rotational velocity,
to process a certain amount of pulp flowing through the refining space 60, is
maintained at a
predefined input power level, which power level is monitored by an operator or
a
controller/processor controlling the first motor 74. For example, if pulp is
moving through the
refining space 60 of a 20 inch diameter Andritz Twinflo IID3 low consistency
refiner at a flow
rate of 151 gallons/minute, and the first motor 74 is running at a constant
rotational speed of 800
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RPM, the second motor 76 is controlled so as to move the second refining
member 30 relative to
the first refining member 20 until the power input by the first motor 74
equals 114 kilowatts. When
the power input by the first motor 74 equals 114 kilowatts, it is presumed
that the gap size between
the first and second refining members 20, 30 is at a value of 0.57 mm.
With continued reference to FIGS. 1, 6A, 6B, 8, and 9, it is believed that the
gap G2, 63,
G4, G4, G5, G6 required to achieve deflaking may vary depending on the load or
flow rate (i.e., the
liters/minute of pulp slurry flowing through the refining space 60) to which
the refining bodies 22,
32/132 are subjected. For example, when the refining bodies 22, 32/132 are
lightly loaded, refining
of the wood fibers may stop and deflaking may begin almost immediately upon
passage of the
fibers into the portion of the refining space 60 that is at least partially
defined by the second refiner
grooves 28B/28B', 38B/3813', e.g., upon movement of the wood fibers past the
first radially
outward position P2/ P2' and/or the third radially outward position P4, as
shown in FIGS. 6A and
6B. When the refining bodies 22, 32/132 are heavily loaded, some refining of
the wood fibers
may continue along at least a portion of the refining space 60 that is at
least partially defined by
the second refiner grooves 28B/28B', 38B/38B'.
In situations in which the refining bodies 22, 32/132 are heavily loaded,
embodiments in
which one or both of the second refiner bars 26B/26B' of the first refining
body 22 and the second
refiner bars 36B/36B' of the second refining body 32 slope continuously
downward may be
particularly advantageous to ensure that a sufficient distance between the
refiner bars 26B/26B'
and 136/36B/36B' is achieved along at least a portion of the refining space 60
that is at least
partially defined by the second refiner grooves 28B/28B', 38B/388' to allow
refining to cease and
deflaking to occur. In addition, the refining surfaces 24, 34 of the refining
bodies 22, 32 may wear
and degrade over time In particular, the first and third refiner bars
26A/26A', 26C, 36A/36A',
36C that perform the majority of the high intensity, high energy refining may
wear faster than the
second and fourth refiner bars 26B/26B', 26D, 36B/36B', 36D that perform
deflaking, which is
generally lower intensity and lower energy than refining. The position of the
refining bodies 22,
32/132 may be adjusted as described herein to maintain the first gap GI
between the first and third
refiner bars 26A/26A', 26C, 36A/36A', 36C at a substantially constant value as
their outer surfaces
S26A, S36A begin to wear down. However, the gap G2, 63, 64, 64, 65, 66 between
the second and
fourth refiner bars 26B/26B', 26D, 36B/36B', 36D may not be adjustable. Thus,
embodiments in
which one or both of the second refiner bars 26B/26B', 36B/36B' and/or one or
both of the four
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refiner bars 36B/368', 36D are sloped are believed to allow the transition
between the refining
and deflaking zones to shift radially outward along the longitudinal length
(not labeled; see FIGS.
6A and 6B) of the second and fourth refiner bars 26B/26B', 26D, 36B/36B', 36D
as the first and
third refiner bars 26A/26A', 26C, 36A/36A', 36C wear down.
FIGS. 10 and 11 are plan views of portions of refining surfaces of a first
refining body 22'
and a second refining body 32', respectively, according to another embodiment
of the present
disclosure. With reference to FIGS. 1, 10, and 11, the first and second
refining bodies 22', 32'
may be part of refining members, e.g., first and second refining members 20,
30, respectively, as
described herein, for use in a pulp refiner, such as the disc refiner 10
depicted in FIG 1 Each of
the refining members 20, 30 comprising the first and second refining bodies
22', 32', respectively,
may be associated with the main support frame comprising the fixed support
frame 66 secured to
the first housing section 12 and the movable support frame 68. One refining
member, e.g., the
first refining member 20 comprising the first refining body 22', may be fixed
to the support frame
66 of the refiner 10 to define a non-rotating stator member. Another refining
member, e.g., a
second refining member 30 comprising the second refining body 32', may be
fixed to the support
70, which rotates with the shaft 72 and defines a rotor that is associated
with the main support
frame, such that rotation of the rotor effects movement of the second refining
member 30 relative
to the first refining member 20 Third and fourth refining members (not shown),
having third and
fourth refining bodies similar to the first and second refining bodies 22',
32', may also be provided.
As shown in FIG. 10, the first refining body 22' comprises a plurality of
sections 22A'-
22C that may be bolted or otherwise attached together to form the disc-shaped
refining body 22'
comprising a radially outer edge 27'. Each section 22A'-22C' comprises a
plurality of elongated
refiner bars 26' separated from one another by refiner grooves 28'. Although
not shown in FIG.
10, it is understood that the other sections (not labeled) of the first
refining body 22' would
similarly comprise refiner bars 26' and refiner grooves 28'. The refiner bars
26' extend radially
outwardly from a radially inner location 23' toward the radially outer edge
27' of the first refining
body 22'. Each section 22A'-22C' of the first refining body 22' may comprise
one or more or
more radially extending pie-shaped segments comprising at least one first pie-
shaped segment
228-1 and at least one second pie-shaped segment 228-2.
As shown in FIG. 11, the second refining body 32' comprises a corresponding
plurality of
sections 32A'-32C' that may be bolted or otherwise attached together to form
the disc-shaped
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refining body 32' comprising a radially outer edge 37'. Each section 32A'-32C'
comprises a
plurality of elongated refiner bars 36' separated from one another by refiner
grooves 38'. Although
not shown in FIG. 11, it is understood that the other sections (not labeled)
of the second refining
body 32' would similarly comprise refiner bars 36' and refiner grooves 38'.
The refiner bars 36'
extend radially outwardly from a radially inner location 33' toward the
radially outer edge 37' of
the second refining body 32'. Each section 32A'-32C' of the second refining
body 32' may
comprise one or more or more radially extending pie-shaped segments comprising
at least one first
pie-shaped segment 32B-1 and at least one second pie-shaped segment 32B-2.
Although not
discussed in detail herein, the third and fourth refining bodies 42, 52 of
FIG. 1 may comprise a
structure that is substantially similar to the first and second refining
bodies 22', 32', respectively,
as described herein.
At least one of the first and second refining bodies 22', 32' of FIGS. 10 and
11 comprises
one or more sections 22K-22C, 32A'-32C' with at least one radially extending
pie-shaped
segment, e.g., 22B-1 and 32B-1, of refiner bars 26', 36' that comprises one or
more characteristics
that are different from the refiner bars 26', 36' in an adjacent radially
extending pie-shaped
segment, e.g., 228-2 and 328-2, respectively. FIGS. 12A and 128 are partial
cross-sectional views
in which the first and second refining bodies 22', 32' of FIGS 10 and 11 are
spaced apart and
positioned adjacent to and across from each other (see FIG. 1). In FIG. 12A, a
first refiner bar 26-
1, which may be located on a refining surface 24-1 of the at least one first
pie-shaped segment
22B-1 of the first refining body 22' (also referred to herein as a first
refining surface), is spaced
apart and positioned adjacent to and across from a third refiner bar 36-1,
which may be located on
a refining surface 34-1 of the at least one third pie-shaped segment 32B-1 of
the second refining
body 32' (also referred to herein as a third refining surface). In FIG. 128, a
second refiner bar 26-
2, which may be located on a refining surface 24-2 of the at least one second
pie-shaped segment
228-2 of the first refining body 22' (also referred to herein as a second
refining surface), is spaced
apart and positioned adjacent to and across from a fourth refiner bar 36-2,
which may be located
on a refining surface 34-2 of the at least one fourth pie-shaped segment 32B-2
of the second
refining body 32' (also referred to herein as a fourth refining surface).
With reference to FIGS. 10, 11, and 12A, the first refiner bars 26-1 are
separated from one
another by first refiner grooves 28-1 and may comprise a first maximum height
Hio extending
upward from a floor Fr of a respective adjacent first refiner groove 28-1. The
third refiner bars
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36-1 are separated from one another by third refiner grooves 38-1 and may
comprise a third
maximum height H30 extending upward from a floor F3' of a respective adjacent
third refiner
groove 38-1. As shown in FIG. 12A, the first and third refiner bars 26-1, 36-1
may be substantially
similar to one another, and the first and third maximum heights Hio, 1130 may
be substantially
equal.
With reference to FIGS. 10, 11, and 12B, the second refiner bars 26-2 are
separated from
one another by second refiner grooves 28-2 and may comprise a second maximum
height 1120
extending upward from a floor Fr of an adjacent second refiner groove 28-2.
The fourth refiner
bars 36-2 are separated from one another by fourth refiner grooves 38-2 and
may comprise a fourth
maximum height H40 extending upward from a floor F4 of an adjacent fourth
refiner groove 38-2.
As shown in FIG. 12B, the second and fourth refiner bars 26-2, 36-2 may be
substantially similar
to one another, and the second and fourth maximum heights H20, H40 may be
substantially equal.
MI of the refiner bars 26-1, 26-2, 36-1, 36-2 within a respective pie-shaped
segment 22B-1, 22B-
2, 32B-1, 32B-2 may comprise a same height with respect to each other.
The second maximum height H20 of the second refiner bars 26-2 may be less than
the first
maximum height Hio of the first refiner bars 26-1. In some examples, the
second maximum height
the, when measured from the floor F2' of the adjacent second refiner groove 28-
2, may be at least
0.35 mm ( 0.05 mm) less than the first maximum height Hie. In other examples,
the second
maximum height H20, when measured from the floor Fr of the adjacent second
refiner groove 28-
2, may be at least 0.7 mm ( 0.05 mm) less than the first maximum height Hio.
In further examples,
the first maximum height Hie of the first refiner bars 26-1, when measured
from the floor Fit of
the respective adjacent first refiner groove 28-1, may be from about 4.0 mm to
about 10.0 mm (+
0.5 mm). This range includes all values and subranges therebetween, including,
for example, 4.0,
4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, 8.0, 8.5, 9.0, 9.5, and 10.0 mm. In a
particular example, the second
maximum height 1120 of the second refiner bars 26-2, when measured from the
floor F2' of the
respective adjacent second refiner groove 28-2, may be from about 0.35 mm to
about 1.5 mm (
0.05 mm) less than the first maximum height Hio. This range includes all
values and subranges
therebetween, including, for example, 0.35, 0.4, 0.45, 0.5, 0.55, 0.6, 0.65,
0.7, 0,75, 0.8, 0,85,0.9,
0.95, 1.0, 1.05, 1,1, 1.15, 1.2, 1,25, 1,3, 1.35, 1.4, 1,45, and 1.5 mm. In
another particular example,
the second maximum height H2o of the second refiner bars 26-2, when measured
from the floor Fr
of the respective adjacent second refiner groove 28-2, may be from about 0.7
min to about 1.5 mm
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( 0.05 mm) less than the first maximum height Hio. This range includes all
values and subranges
therebetween, including, for example, 0.7, 0.75, 0.8, 0.85, 0.9,0.95, 1.0,
1.05, 1.1, 1.15, 1.2, 1.25,
1.3, 1.35, 1.4, 1.45, and 1.5 mm. In further examples, the first refiner bars
26-1 and the second
refiner bars 26-2 may comprise a width extending between sides edges of the
respective refiner
bars 26-1, 26-2 of from about 2.0 mm to about 8.0 mm (not shown; see FIG. 7).
This range
includes all values and subranges therebetween, including, for example, 2.0,
2.5, 3.0, 3.5, 4.0, 4.5,
5.0, 5.5, 6.0, 6.5, 7.0, 7.5, and 8.0 mm. The fourth maximum height 1140 of
the fourth refiner bars
36-2, which may correspond to the second maximum height H2o, may be less than
the third
maximum height H30 of the third refiner bars 36-1, which may correspond to the
first maximum
height Hio.
With reference to FIGS. 1, 10, 11, 12A, and 12B, as the second refining member
30 rotates
relative to the first refining member 20, the refining surface 34-1 of the at
least one third pie-
shaped segment 32B-1 of the second refining body 32' will pass the refining
surface 24-1 of the
at least one first pie-shaped segment 22B-1 of the first refining body 22',
and the refining surface
34-2 of the at least one fourth pie-shaped segment 32B-2 of the second
refining body 32' will pass
the refining surface 24-2 of the at least one second pie-shaped segment 22B-2
of the first refining
body 22'. When a slurry of wood pulp is supplied to the frame 66, e.g., the
inlet 16, of the refiner
10 and passes through the refining space 60, and the refining surface 34-1 of
the at least one third
pie-shaped segment 32B-1 of the second refining body 32' passes the refining
surface 24-1 of the
at least one first pie-shaped segment 22B-1 of the first refining body 22',
the third refiner bars 36-
1 comprising the third maximum height H30 will be positioned opposite the
first refiner bars 26-1
comprising the first maximum height Hio such that the first and third refiner
bars 26-1 and 36-1
refine a significant number of the wood fibers. When the refining surface 34-2
of the at least one
fourth pie-shaped segment 32B-2 of the second refining body 32' passes the
refining surface 24-2
of the at least one second pie-shaped segment 22B-2 of the first refining body
22', the fourth refiner
bars 36-2 comprising the fourth maximum height H40 will be positioned opposite
from the second
refiner bars 26-2 comprising the second maximum height H2o such that the
second and fourth
refiner bars 26-2 and 36-2 break up or separate a plurality of wood fiber
bundles in the wood pulp
slurry, as described herein. Low intensity refining may occur when the
refining surface 34-1 of
the at least one third pie-shaped segment 32B-1 of the second refining body
32' passes the refining
surface 24-2 of the at least one second pie-shaped segment 22B-2 of the first
refining body 22',
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and the refining surface 34-2 of the at least one fourth pie-shaped segment
32B-2 of the second
refining body 32' passes the refining surface 24-1 of the at least one first
pie-shaped segment 22B-
1 of the first refining body 22'.
As shown in FIGS. 10 and 11, one or more of the sections 22A'-22C, 32A'-32C'
of the
respective refining bodies 22', 32' may, in some examples, each comprise three
radially extending
pie-shaped segments 22B-1, 22B-1, 22B-3 and 32B-1, 32B-2, 32B-3. In some
particular examples,
two segments, e.g., 22B-1, 22B-3 and 32B-1, 32B-3, may comprise refiner bars
with one of the
first or second maximum height Hio, 1120, and one segment, e.g., 22B-2 and 32B-
2, may comprise
refiner bars with the other of the first or second maximum height the, I-12o,
in which the second
maximum height Hio is less than the first maximum height Hio. For example, the
segments 22B-
1, 22B-3 may comprise the first refiner bars 26-1, the segments 32B-1, 32B-3
may comprise third
refiner bars 36-1, the segment 22B-2 may comprise the second refiner bars 26-
2, and the segment
32B-2 may comprise the fourth refiner bars 36-2. In other examples (not
shown), one or more of
the sections 22A'-22C', 32A'-32C' may each comprise only two segments of
refiner bars or may
each comprise four or more segments of refiner bars. In further examples (not
shown), one or
more of the sections 22A'-22C, 32A'-32C' may not comprise separate segments,
such that an
entire section comprises refiner bars of one height. It is understood that a
refining body according
to the present disclosure, e.g., one of refining bodies 22', 32', may be
paired with a refining body
comprising conventional refiner bars, e.g., refiner bars that are all of the
same height.
It is believed that a gap between opposing first and third refiner bars 26-1,
36-1 should be
less than about 0.9 mm (+ 0.05 mm) and preferably from about 0.2 mm to about
0.9 mm (+ 0.05
mm) in order for refining to occur and that a gap between opposing second and
fourth refiner bars
26-2, 36-2 should be from about 0.9 mm to about 1.5 mm 0.05 mm) in order for
deflalcing to
occur. Each of these ranges include all values and subranges therebetween,
including, for example,
0.2, 0.25, 0.3, 0.35, 0.4, 0.45, 0.5, 0.55, 0.6, 0.65, 0.7, 0.75, 0.8, 0.85,
and 0.9 mm for the range of
about 0.2 mm to about 0.9 mm, and 0.9, 0.95, 1.0, 1.05, 1.1, 1.15, 1.2, 125,
1.3, 1.35, 1.4, 1.45,
and 1.5 mm for the range of about 0.9 mm to about 1.5 mm. In some examples,
the gap between
opposing first and third refiner bars 26-1, 36-1 may be from about 0.1 mm to
about 0.5 mm (+ 0.05
mm). This range includes all values and subranges therebetween, including, for
example, 0.1,
0.15, 0.2, 0.25, 0.3, 0.35, 0.4, 0.45, and 0.5 mm.
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FIGS. 19A and 19B are partial cross-sectional views similar to FIGS. 6A and 6B
of first
refining bodies 1022, 1022' with a respective first refining surface 1024,
1024' and second refining
bodies 1032, 1032' with a respective second refining surface 1034, 1034'. As
described herein in
detail, the first and second refining bodies 1022/1022', 1032/1032' may be
part of refining
members, e.g., refining members 20, 30, respectively, in FIG. 1, for use in a
pulp refiner, such as
the disc refiner 10 depicted in FIG. 1. Each of the refining members 20, 30
comprising the first
and second refining bodies 1022/1022', 1032/1032' may be associated with the
main support
frame comprising the fixed support frame 66 secured to the first housing
section 12 and the
movable support frame 68. One refining member, e.g., the first refining member
20 comprising
the first refining body 1022/1022A', may be fixed to the support frame 66 of
the refiner 10 to
define a non-rotating stator member. Another refining member, e.g., the second
refining member
30 comprising the second refining body 1032/1032', may be fixed to the support
70, which rotates
with the shaft 72 and defines a rotor that is associated with the main support
frame, such that
rotation of the rotor effects movement of the second refining member 30
relative to the first
refining member 20. The first and second refining bodies 1022/1022',
1032/1032' may each
comprise a plurality of sections (not shown; see 22A-22C and 32A-32C in FIGS.
2 and 3) that may
be bolted or otherwise attached together to form a disc-shaped refining body
comprising a
respective radially inner edge 1023, 1023' and 1033, 1033' and radially outer
edge 1027, 1027'
and 1037, 1037'.
With reference to FIG. 19A, the refining surfaces 1024, 1034 may each comprise
a plurality
of elongated refiner bars 1026, 1036 comprising first refiner bars 1026A,
1036A and second refiner
bars 1026B, 1036B separated from one another by respective first refiner
grooves 1028A, 1038A
and second refiner grooves 10288, 1038B (the first and second refiner bars
1026A/1036A and
10268/10368 may also be referred to herein as first and second refiner bar
elements). In some
examples, the first and second refiner grooves 10284, 1028B and 1038A, 1038B
may have a width
(not shown; see WG in FIGS. 4A and 5A) of from about 2.0 mm to about 6.0 mm,
and the first and
second refiner bars 1026A, 1026B and 1036A and 1036B may comprise a width (not
shown; see
W26 in FIG. 7) of from about 2.0 mm to about 8.0 mm. Each of these ranges
include all values
and subranges therebetween, including, for example, 2.0, 2.5, 3,0, 3,5, 4,0,
4.5, 5,0, 5.5, and 6.0
mm for the range of about 2.0 mm to about 6.0 mm, and 2.0, 2.5, 3.0, 3.5, 4.0,
4.5, 5.0, 5.5, 6.0,
6.5, 7.0, 7.5, and 8.0 mm for the range of about 2.0 mm to about 8.0 mm. The
refiner bars 1026,
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1036 may be slanted at various angles on the respective refining surfaces
1024, 1034, and each
section of the refining body 1022, 1032 may comprise one or more segments (not
labeled) of
refiner bars 1026, 1036 that are slanted in different directions (not shown;
see FIGS. 2 and 3).
The first and second refiner bars 1026, 1036 each extend radially outwardly
from a radially
inner location, i.e., the radially inner edge 1023, 1033, toward the radially
outer edge 1027, 1037
of the respective refining body 1022, 1032. In particular, each of the first
refiner bars 1026A,
1036A extend from a first radially inward position Pim on the refining
surface 1024, 1034 to a
first radially outward position P2000 on the refining surface 1024, 1034. Each
of the second refiner
bars 102613, 103613 extend from a second radially inward position on the
refining surface 1024,
1034, as described herein, to a second radially outward position P3000 on the
refining surface 1024,
1034, in which the second radially outward position P3000 may be nearer to an
outermost part of
the refining body 1022, 1032, e.g., the radially outer edge 1027, 1037, in a
general direction of
travel of the wood fibers, than the first radially outward position P2000. In
some examples, the first
radially inward position Pio may comprise a position at or near the radially
inner edge 1023,
1033. In some embodiments, the second refiner bars 1026B, 1036B may be
integral with the first
refiner bars 1026A, 1036A, such that the second radially inward position of
the second refiner bars
102613, 103613 is substantially the same as the first radially outward
position P2000 of the first
refiner bars 1026A, 1036A and the second refiner bars 10268, 10368 extend from
the first radially
outward position P2000 to the second radially outward position P3000. In other
embodiments (not
shown), the first refiner bars 1026A, 1036A may be radially separated from the
second refiner bars
1026B, 1036B by a space. The second refiner bars 1026B, 1036B may comprise a
longitudinal
length Li000 from about 0.6 cm to about 10 cm, and preferably from about 2 cm
to about 10 cm.
As described above, the refining surfaces 1024, 1034 may comprise dams (not
shown; see 29 and
39 in FIGS. 4A, SA, and 7) provided in at least a portion of the first refiner
grooves 1028A, 1038A,
in which the dams may comprise a height that is substantially the same as or
less than the height
of the adjacent first refiner bars 1026A, 1036A.
With continued reference to FIG. 19A, the first refiner bars 1026A, 1036A
comprise a first
height Hi000 extending upward from a floor F t000 of the adjacent first
refiner groove 1028A, 1038A.
In some examples, the first height Hi000 may be a maximum height of the first
refiner bars 1026A,
1036A. The first refiner bars 1026A, 1036A may extend substantially
horizontally such that the
first height Moo may be substantially constant along a longitudinal length
(not labeled) of the first
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refiner bars 1026A, 1036A, e.g., between the first radially inward position
Pi000 and the first
radially outward position P2000, as shown in the example in FIG. 19A. In some
examples, the first
height Hi000 of the first refiner bars 1026A, 1036A, when measured from the
floor Fi000 of the
adjacent first refiner groove 1028A, 1038A, may be from about 4.0 mm to about
10.0 mm 0.5
mm). This range includes all values and subranges therebetween, including, for
example, 4.0, 4.5,
5.0, 5.5, 6.0, 6.5, 7.0, 7.5, 8.0, 8.5, 9.0, 9.5, and 10.0 mm.
The second refiner bars 1026B, 10368 comprise a second height Mow extending
upward
from a floor F2000 of the adjacent second refiner groove 1028B, 1038B, in
which the second height
H2000 is a minimum height of the second refiner bars 102611, 10368 and is
spaced apart from the
second radially inward position, e.g., P2000, of the second refiner bars 1026B
and 10368 (the first
and second heights H1000, H2000 may also be referred to herein as the first
and second bar heights).
In some embodiments, the second height H2000 of the second refiner bars 1026B,
1036B extending
upward from the floor Film of the adjacent second refiner groove 1028B, 10388
may be greater
than zero, as shown with a solid line in FIG. 19A. For example, the second
height Mom may be
from about 2.0 mm to about 40 mm ( 0.2 mm). This range includes all values
and subranges
therebetween, including, for example, 2.0, 2.2, 2.4, 2.6, 2.8, 3.0, 3.2, 3.4,
3.6, 3.8, and 4.0 nun. In
other embodiments, the second height H2000 may be slightly greater than zero,
e.g., the second
refiner bars 1026B, 1036B at their minimum height may be slightly above level
or flush with the
floor F2000 of the adjacent second refiner groove 1028B, 1038B, as shown with
a dashed line in
FIG. 19A.
The second height H2000 of the second refiner bars 1026B, 1036B may be at
least about
0.35 mm (+ 0.05 mm) less than the first height Ht000 of the first refiner bars
1026A, 1036A. In
some examples, the second height Thocio may be at least 0.7 mm ( 0.05 min)
less than the first
height Mom In some particular examples, the second height thew of the second
refiner bars
1026B, 1036B, when measured from the floor F2000 of the adjacent second
refiner groove 1028B,
103811, may be from about 0.35 mm to about 7.0 mm ( 0.05 min) less than the
first height Him .
This range includes all values and subranges therebetween, including, for
example, 0.35, 0.5, 1.0,
1.5, 2.0, 2,5, 3.0, 3.5, 4.0, 4.5, 5,0, 5.5, 6,0, 6,5, and 7.0 mm. In other
particular examples, the
second height 1-12000 may be from about 0.7 mm to about 7,0 mm (+ 0.05 mm)
less than the first
height Elmo. This range includes all values and subranges therebetween,
including, for example,
0.7, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, and 7.0 mm.
In further particular
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examples, the second height H2000 may be from about 0.7 mm to about 5.0 mm (
0.05 mm) less
than the first height Ht000, or from about 2.0 mm to about 3.0 mm ( 0.05 mm)
less than the first
height Ht000. Each of these ranges include all values and subranges
therebetween, including, for
example, 0.7, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, and 4.5 mm for the range
of about 0.7 mm to
about 5.0 mm, and 2,0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2,7, 2.8, 2,9, and 3,0 mm
for the range of about
2.0 mm to about 3.0 mm. In embodiments in which the second height H2000 is
slightly greater than
zero, a difference between the first and second heights Moo , 1-12000 may be
substantially an entirety
of the height of the first refiner bars 1026A, 1036A. For example, where the
first height Hum of
the first refiner bars 1026A, 1036A is about 10.0 mm, the second height H2000
of the second refiner
bars 1026B, 1036B may be about 10.0 mm less than the first height Ht000.
As shown in FIG. 19A, in some examples, the second refiner bars 1026B, 1036B
may slope
substantially continuously downward along at least a portion of each second
refiner bar 1026B,
1036B extending between the first radially outward position P2000 to the
second radially outward
position P3000. In some particular examples, the height of the second refiner
bars 102613, 103613
may decrease continuously along substantially an entire longitudinal length
Li000 of the second
refiner bars 102613, 103613. For instance, the second refiner bars 102613,
103613 may have a
maximum height (not separately labeled) that occurs at a position adjacent to
the first radially
outward position P200o and that is substantially the same as the first height
Hi000 of the first refiner
bars 1026A, 1036A, with the second refiner bars 1026B, 1036B sloping
substantially continuously
downward from the first radially outward position P2000 to the second radially
outward position
P3000. The second (minimum) height H2000 of the second refiner bars 1026B,
1036B may occur at
a position that is adjacent to the second radially outward position P3000.
In some examples, the first and second refining members 20, 30 comprising the
first and
second refining bodies 1022, 1032 may be arranged such that the first refining
surface 1024 faces
the second refining surface 1034 (not shown; see, for example, FIGS. 1, 8, and
9), in which the
first refining member 20 is spaced apart from the second refining member 30 to
define a refining
space (see 60 in FIG. 1) between the respective refining surfaces 1024, 1034,
as described herein
in detail. At least a portion of the refiner bars 1026 of the first refining
body 1022 may be
positioned so as to be across from, i.e., facing, at least a portion of the
refiner bars 1036 of the
second refining body 1032 to define a gap (see FIGS. 8 and 9) between the
opposing portions of
the refiner bars 1026, 1036. In particular, at least a portion of the first
refiner bars 1026A of the
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first refining body 1022 may be positioned so as to be across from, i.e.,
facing, at least a portion
of the first refiner bars 1036A of the second refining body 1032, and at least
a portion of the second
refiner bars 1026B of the first refining body 1022 may be positioned so as to
be across from, i.e.,
facing, at least a portion of the second refiner bars 1036B of the second
refining body 1032.
As a slurry of wood pulp comprising wood fibers is supplied to the frame 66 of
the refiner
as shown in FIG. 1 and described above, an axial force or pressure may be
applied to one or
both of the refining members 20, 30, which adjusts the size of the gap defined
between the first
and second refining members 20, 30. The first refiner bars 1026A, 1036A may be
adapted to refine
the wood fibers in the pulp slurry, while the second refiner bars 10268, 10368
may be adapted to
10 break up or separate fiber bundles. Because the first height Hi000 of
the first refiner bars 1026A,
1036A is greater than the second height 1-2000 of the second refiner bars
1026B, 1036B, the wood
fibers are subjected to high intensity shearing and compression forces as the
fibers pass through
the portion of the refining space that is at least partially defined by the
first refiner grooves 1028A,
1038A (e.g., a refining zone, as described above). The first refiner bars
1026A, 1036A interact
with one another or with the conventional refiner bars to refine a significant
number of the wood
fibers in the wood pulp. When the fibers pass into the portion of the refining
space that is at least
partially defined by the second refiner grooves 10288, 10388 (e.g., a
deflaking zone, as described
above), the intensity of the force applied to the fibers decreases in response
to the reduced height,
which is believed to break up or separate a plurality of the wood fiber
bundles formed during
refining without further refining or only minimally refining the fibers.
In this example, the gap between opposing portions of the second refiner bars
1026B,
1036B may be from about 0.9 mm to about 20.0 mm 0.05 mm). This range includes
all values
and subranges therebetween, including, for example, 0.9, 1.0, 1.5, 2.0, 2.5,
3.0, 3.5, 4.0, 4.5, 5.0,
5.5, 6.0, 6.5, 7.0, 7.5, 8.0, 8.5, 9.0, 9.5, 10.0, 10.5, 11.0, 11.5, 12.0,
12.5, 13.0, 13.5, 14.0, 14.5,
15.0, 15.5, 16.0, 16.5, 17.0, 17.5, 18.0, 18.5, 19.0, 19.5, and 20.0 mm. In
embodiments in which
the second refiner bars 10268 and/or 10368 slope substantially continuously
downward along at
least a portion of the second refiner bar 1026B, 1036B, the gap may increase
along at least a section
of the second refiner bars 10268, 1036B in a radially outward direction, i.e.,
in a direction
extending from the second radially inward position (e.g., Pnoo) to the second
radially outward
position P3000 of the second refiner bars 1026B, 1036B. In some examples, the
gap may increase
along substantially an entirety of the longitudinal length Lw of the second
refiner bars 1026B,
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1036B. It is believed that the second (minimum) height H2000 of the second
refiner bars 1026B,
1036B should be at least about 0.35 mm ( 0.05 mm) less than the first height
Hi000 of the first
refiner bars 1026A, 1036A in order to cease refining of the fibers and begin
deflaking.
In other examples, one of the refining bodies 1022, 1032 shown in FIG. 19A may
be paired
with a conventional refining body (not shown; see 132 in FIG. 8) that
comprises conventional
refiner bars with a uniform height along substantially an entirety of their
longitudinal length. For
instance, the first refining member 20 may comprise the first refining body
1022, and the second
refining member 30 may comprise the conventional refining body. The refining
members 20, 30
may be arranged such that they face each other, with at least a portion of the
first and second refiner
bars 1026A, 1026B being positioned so as to be across from, i.e., facing, at
least a portion of the
conventional refiner bars to define a gap (see FIGS. 8 and 9) between the
opposing portions. As
described herein, a slurry of wood pulp may be supplied, and an axial force or
pressure may be
applied to one or both of the refining members 20, 30 to adjust the size of
the gap, with the first
refiner bars 1026A being adapted to refine the wood fibers in the pulp slurry
and the second refiner
bars 1026B being adapted to break up or separate fiber bundles. In this
example, the gap between
opposing portions of the second refiner bars 10268 and the conventional
refiner bars may be from
about 0.9 mm to about 10.0 mm ( 0.05 mm). This range includes all values and
subranges
therebetween, including, for example, 0.9, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0,
4.5, 5.0, 5.5, 6.0, 6.5,
7.0, 7.5, 8.0, 8.5, 9.0, 9.5, and 10.0 mm. In embodiments in which the second
refiner bars 1026B
slope, the gap may increase along at least a section of the second refiner
bars 1026B in a radially
outward direction, as described herein, and may increase along substantially
an entirety of the
longitudinal length Lt000 of the second refiner bars 1026B. In this example,
it is believed that the
second (minimum) height H2000 of the second refiner bars 102613 should be at
least about 0.7 mm
less ( 0.05 mm) than the first height limo of the first refiner bars
1026A/1036A in order to cease
refining of the fibers and begin deflalcing.
In both examples, it is believed that the gap between opposing portions of the
refiner bars
should be less than about 0.9 mm (+ 0.05 mm) in order for refining to occur
(e.g., between opposing
portions of the first refiner bars 1026A, 1036A or between opposing portions
of the first refiner
bars 1026A/1036A and the conventional refiner bars). In some instances, the
gap in the refining
zone may be less than about 0.7 mm ( 0.05 mm). In some particular instances,
the gap may be
from about 0.1 mm to about 0.5 mm 0.05 mm). This range includes all values and
subranges
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therebetween, including, for example, 0.1, 0.15, 0.2, 0.25, 0.3, 0.35, 0.4,
0.45, and 0.5 mm. It is
also believed that the gap should be from about 0.9 mm to about 2.0 min (
0.05 mm) in order for
deflaking to occur (e.g., between opposing portions of the second refiner bars
1026B, 1036B or
between opposing portions of the second refiner bars 1026B/1036B and the
conventional refiner
bars). This range includes all values and subranges therebetween, including,
for example, 0.9, 1.0,
1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, and 2.0 mm. As noted above, the
gap along at least a
portion of the second refiner bars 1026B/1036B may be much larger than about
2.0 mm, e.g., up
to about 20.0 mm in some instances. This larger gap may be used to account for
inevitable wear
that will reduce the heights Hi000, Hz000 of the refiner bars 1026A, 1036A,
10268, 10368. The
position of the refining bodies may be adjusted as described herein to
maintain the gap at a desired
value as the refining surfaces begin to wear down. In particular, embodiments
in which the second
refiner bars 1026B, 1036B slope substantially continuously downward along at
least a portion of
each second refiner bar 1026B, 1036B are believed to allow the transition
between the refining
and deflaking zones to shift radially outward along the longitudinal length
Li000 of the second
refiner bars 1026B, 1036B, such that a gap of about 0.9 mm to about 2.0 mm for
deflaking may be
maintained throughout the life of the refining members.
With reference to FIG. 1911, the refining bodies 1022', 1032' may comprise
respective
refining surfaces 1024', 1034' that each include a plurality of elongated
refiner bars 1026', 1036'
comprising first refiner bars 1026A', 1036K, second refiner bars 1026B',
1036B', third refiner
bars 1026C, 1036C, and fourth refiner bars 1026D, 1036D. The first and second
refiner bars
1026A', 1036A', 1026B', 1036B' may be substantially similar to the first and
second refiner bars
1026A, 1036A, 1026B, 1036B, as depicted in FIG. 19A and described herein. The
first refiner
bars 1026A', 1036A' may be separated from one another by first refiner grooves
1028A', 1038A',
and the second refiner bars 1026B', 103611' may be separated from one another
by second refiner
grooves 102811', 103811'. The third refiner bars 1026C, 1036C may be separated
from one another
by third refiner grooves 1028C, 1038C, and the fourth refiner bars 1026D,
1036D may be separated
from one another by fourth refiner grooves 1028D, 1038D.
Each of the first refiner bars 1026K, 1036K may extend from a first radially
inward
position Pl000' to a first radially outward position P2000' on the refining
surface 1024', 1034', Each
of the second refiner bars 1026B', 1036B' may extend from a second radially
inward position on
the refining surface 1024', 1034', as described herein, to a second radially
outward position P3000'
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on the refining surface 1024', 1034'. Each of the third refiner bars 1026C,
1036C may extend
from a third radially inward position on the refining surface 1024', 1034', as
described herein, to
a third radially outward position Now on the refining surface 1024', 1034'.
Each of the fourth
refiner bars 1026D, 103613 may extend from a fourth radially inward position
on the refining
surface 1024', 1034', as described herein, to a fourth radially outward
position Ps000 on the refining
surface 1024', 1034'. The fourth radially outward position Ps000 may be nearer
to an outermost
part, e.g., the radially outer edge 1027', 1037', of the refining body 1022',
1032' than the first,
second, and third radially outward positions P2000r, Pyor and N000. The second
and fourth refiner
bars 102687103613' and 1026D/1036D may comprise a respective longitudinal
length bow', L2000
of about 0.6 cm to about 10 cm, and preferably of about 2 cm to about 10 cm.
In some examples,
the first and/or second refiner bars 1026A', 1036A', 1026B', 1036W may extend
radially
outwardly a shorter distance, as compared to the first and second refiner bars
1026A, 1036A,
1026B, 1036B. As described above, the refining surfaces 1024', 1034' may
comprise dams (not
shown; see 29 and 39 in FIGS. 413 and 513) provided in at least a portion of
the first and third
refiner grooves 1028A'/1038A' and 1028C/1038C, in which the dams may comprise
a height that
is substantially the same as or less than the height of the adjacent first
and/or third refiner bars
1026A71036A' and 1026C/1036C.
In some embodiments, as shown in FIG. 19B, the second refiner bars 102613',
1036B' may
be integral with the first refiner bars 1026A', 1036K, the third refiner bars
1026C, 1036C may be
integral with the second refiner bars 1026B', 1036B'; and/or the fourth
refiner bars 10261), 103613
may be integral with the third refiner bars 1026C, 1036C. For example, when
the first and second
refiner bars 1026A'/1036A' and 1026B'/1036B' are integral with each other, the
second radially
inward position of the second refiner bars 102613', 10368' may be
substantially the same as the
first radially outward position P2000' of the first refiner bars 1026A',
1036A', and the second refiner
bars 102611', 1036B' may extend from the first radially outward position
P2000' to the second
radially outward position P3000'. When the second and third refiner bars
1026137103613' and
1026C/1036C are integral with each other, the third radially inward position
of the third refiner
bars 1026C, 1036C may be substantially the same as the second radially outward
position P3000' of
the second refiner bars 1026B', 1036B', and the third refiner bars 1026C,
1036C may extend from
the second radially outward position P3000' to the third radially outward
position P4000. When the
third and fourth refiner bars 1026C/1036C and 1026D/1036D are integral with
each other, the
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fourth radially inward position of the fourth refiner bars 1026D, 1036D may be
substantially the
same as the third radially outward position P4000 of the third refiner bars
1026C, 1036C, and the
fourth refiner bars 1026D, 10360 may extend from the third radially outward
position Kt000 to the
fourth radially outward position Ps000. In other embodiments (not shown), the
first refiner bars
1026A', 1036A' may be radially separated from the second refiner bars 1026B',
1036W by a
space, the second refiner bars 1026B', 1036B' may be radially separated from
the third refiner
bars 1026C, 1036C by a space, and/or the third refiner bars 1026C, 1036C may
be radially
separated from the fourth refiner bars 1026D, 1036D by a space.
With continued reference to FIG. 198, the first and third refiner bars
1026A'/1036A' and
1026C/1036C comprise a respective first height Ht000. and third height H3000
extending upward
from a floor F1000', F3000 of the respective adjacent first and third refiner
grooves 1028A'/1038A'
and 1028C/1038C. The first and third heights Hioow,113000 may be a maximum
height of the first
and third refiner bars 1026A'/1036A' and 1026C/1036C, respectively. In some
examples, the first
and third refiner bars 1026A'/1036A' and 1026C/1036C may extend substantially
horizontally
such that the first and third heights Htoow, lb000 may be substantially
constant along a longitudinal
length (not labeled) of the first and third refiner bars 1026A71036A' and
1026C/1036C, e.g.,
between the first radially inward position Pioow and the first radially
outward position Pz000' for the
first refiner bars 1026A', 1036A' and between the third radially inward
position, e.g., P3000' and
the third radially outward position P.t000 for the third refiner bars 1026C,
1036C. In some examples,
the first and third heights H1000', H3000 of the first and third refiner bars
1026A'/1036A' and
1026C/1036C, when measured from the floor F1000', F3000 of the respective
adjacent first and third
refiner grooves 1028A'/1038A' and 1028C/1038C, may be from about 4.0 mm to
about 10.0 mm
( 0,5 mm). This range includes all values and subranges therebetween,
including, for example,
4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, 8.0, 8.5, 9.0, 9.5, and 10.0 mm.
The second and fourth refiner bars 1026W/103611' and 1026D/1036D may comprise
a
respective second height H2000' and fourth height Hum extending upward from a
floor F200.0', F400.0
of the respective adjacent second and fourth refiner grooves 1028B'/1038B' and
1028D/1038Di
The second height H2000' is a minimum height of the second refiner bars
102613', 103613' and is
spaced apart from the second radially inward position, e.g., P2090', of the
second refiner bars
1026B', 1036B'. The fourth height H4000 is a minimum height of the fourth
refiner bars 1026D,
1036D and is spaced apart from the fourth radially inward position, e.g.,
P4000, of the fourth refiner
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bars 1026D, 1036D. In some embodiments, the second height 11.2000' of the
second refiner bars
1026W, 1036B' extending upward from the floor F2000' of the adjacent second
refiner groove
1028B', 1038B' and/or the fourth height Fizi000 of the fourth refiner bars
1026D, 103613 extending
upward from the floor Et000 of the adjacent fourth refiner groove 1028D,
10381) may be greater
than zero, as shown with a solid line in FIG. 19B. For example, the second
height H2000' and/or
the fourth height 'how may be from about 2.0 mm to about 4.0 mm (+ 0.2 mm).
This range
includes all values and subranges therebetween, including, for example, 2.0,
2.2, 2.4, 2.6, 2.8, 3.0,
3.2, 3.4, 3.6, 3.8, and 4.0 mm. In other embodiments, the second height th000'
and/or the fourth
height Th000 may be slightly greater than zero, e.g., the second refiner bars
102611', 103611' and/or
the fourth refiner bars 1026D, 1036D at their minimum height may be slightly
above level or flush
with the floor F20001, F4000 of the respective adjacent second or fourth
refiner grooves
1028W/1038W, 1028D/1038D, as shown with a dashed line in FIG. 19B.
The second height H2000' of the second refiner bars 1026B', 1036B' and/or the
fourth height
Ri000 of the fourth refiner bars 1026D, 1036D may be at least about 0.35 mm
0.05 mm) less
than the first height Hi000' of the first refiner bars 1026A', 1036A' and/or
the third height H3000 of
the third refiner bars 1026C, 1036C, respectively. In some examples, the
second height H2000' and
the fourth height Moo may be at least 010 mm 0.05 mm) less than the first
height Hi000' and
the third height H3000, respectively. In some particular examples, the second
height H2000' of the
second refiner bars 1026B', 1036W, when measured from the floor F2000' of the
adjacent second
refiner groove 1028B', 1038B', and/or the fourth height H4000 of the fourth
refiner bars 102613,
1036D, when measured from the floor F4000 of the adjacent fourth refiner
groove 10281), 10381),
may be from about 0.35 mm to about 7.0 mm (40,05 mm) less than the first
height Moor and the
third height H3000, respectively. This range includes all values and subranges
therebetween,
including, for example, 0.35, 0.5, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5,
5.0, 5.5, 6.0, 6.5, and 7.0 mm.
In other particular examples, the second height H200.0' and the fourth height
How may be from
about 0.7 mm to about 7.0 mm ( 0.05 mm) less than the first height Htooty and
the third height
H3000, respectively. This range includes all values and subranges
therebetween, including, for
example, 0.7, 1.0, 1.5, 2.0, 2.5, 3.0, 3,5, 4,0, 4,5, 5.0, 5,5, 6,0, 6.5, and
7.0 mm. In further particular
examples, the second height Moor and the fourth height RION may be from about
0.7 mm to about
5.0 mm ( 0.05 mm) less than the first height Flicor and the third height
H3000, respectively, or
from about 2.0 mm to about 3.0 mm ( 0.05 mm) less than the first height Mow
and the third
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height H3000, respectively. Each of these ranges include all values and
subranges therebetween,
including, for example, 0.7, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0,4.5, and 4.5 mm
for the range of about
0.7 mm to about 5.0 mm, and 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9,
and 3.0 mm for the range
of about 2.0 mm to about 3.0 mm. In embodiments in which the second and/or
fourth heights
H2000', H4000 are slightly greater than zero, a difference between the first
and second heights H1000',
H2000' and/or between the third and fourth heights H3000, H4000 may be
substantially an entirety of
the height of the first and/or third refiner bars 1026A'/1036A' and
1026C/1036C. For example,
where the first and third heights 111000', 113000 are about 10.0 mm, the
second and fourth heights
H2000', H4000 may be about 10.0 mm less than the first and third heights
H1000', H3000,
As shown in FIG. 19B, in some examples, the second refiner bars 1026B', 1036B'
and/or
the fourth refiner bars 1026D, 1036D may slope substantially continuously
downward along at
least a portion of each refiner bar 10268', 10368', 1026D, 1036D. For example,
the second refiner
bars 1026B', 1036B' may slope substantially continuously downward along at
least a portion
extending between the first radially outward position P2000' to the second
radially outward position
P3000, and/or the fourth refiner bars 1026D, 1036D may slope substantially
continuously downward
along at least a portion extending between the third radially outward position
Now to the fourth
radially outward position Ps000. In some particular examples, the height of
the second refiner bars
1026W, 10368' and/or the fourth refiner bars 1026D, 1036D may decrease
continuously along
substantially their entire respective longitudinal length Lt000-, L2000. For
instance, the second
refiner bars 1026B', 1036B' may have a maximum height (not separately labeled)
that occurs at a
position that is adjacent to the first radially outward position P2000' and
that is substantially the
same as the first height Ht000. of the first refiner bars 1026A', 1036N, with
the second refiner bars
102613', 103613' sloping substantially continuously downward from the first
radially outward
position P2000- to the second radially outward position P3000'. The fourth
refiner bars 1026D, 1036D
may similarly have a maximum height (not separately labeled) that occurs at a
position that is
adjacent to the third radially outward position P4000 and that is
substantially the same as the third
height H3000 of the third refiner bars 1026C, 1036C, with the fourth refiner
bars 1026D, 103613
sloping substantially continuously downward from the third radially outward
position P4000 to the
fourth radially outward position Ps000, The second (minimum) height H2000' of
the second refiner
bars 1026B', 1036B' may occur at a position that is adjacent to the second
radially outward
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position P3000', and the fourth (minimum) height 114000 of the fourth refiner
bars 1026D, 1036D
may occur at a position that is adjacent to the fourth radially outward
position Ps000.
In some examples, the first and second refining members 20, 30 comprising the
first and
second refining bodies 1022', 1032' may be arranged such that the first and
second refining
surfaces 1024', 1034' face each other (not shown; see, for example, FIGS. 1,
8, and 9) and define
a refining space (see 60 in FIG. 1), as described herein in detail. At least a
portion of the refiner
bars 1026' of the first refining body 1022' are positioned so as to be across
from, i.e., facing, at
least a portion of the refiner bars 1036' of the second refining body 1032' to
define a gap (see
FIGS. 8 and 9) between the opposing portions of the refiner bars 1026', 1036'
In particular, at
least a portion of the first refiner bars 1026A' of the first refining body
1022' may be positioned
so as to be across from, i.e., facing, at least a portion of the first refiner
bars 1036K of the second
refining body 1032'; at least a portion of the second refiner bars 1026B' may
be positioned so as
to be across from, i.e., facing, at least a portion of the second refiner bars
1036B', at least a portion
of the third refiner bars 1026C may be positioned so as to be across from,
i.e., facing, at least a
portion of the third refiner bars 1036C; and at least a portion of the fourth
refiner bars 1026D may
be positioned so as to be across from, i e , facing, at least a portion of the
fourth refiner bars 1036D.
As a slurry of wood pulp comprising wood fibers is supplied to the frame 66 of
the refiner
10 as shown in FIG. I and described above, an axial force or pressure may be
applied to one or
both of the refining members 20, 30, which adjusts the size of the gap defined
between the first
and second refining members 20, 30. The first and third refiner bars
1026A'/1036A' and
1026C/1036C may be adapted to refine the wood fibers in the pulp slurry, while
the second and
fourth refiner bars 1026B'/1036B' and 1026D/1036D may be adapted to break up
or separate fiber
bundles Because the first and third heights Him . and H3000 of the first and
third refiner bars
1026A71036A' and 1026C/1036C are greater than the respective second and fourth
heights H2000'
and 114000 of the second and fourth refiner bars 1026B'/1036B' and
1026D/1036D, the wood fibers
are subjected to high intensity shearing and compression forces as the fibers
pass through the
portion of the refining space that is at least partially defined by the first
and third refiner grooves
1028K/1038A' and 1028C/1038C (e.g., first and second refining zones, as
described above). The
first and third refiner bars 1026A'/1036A' and 1026C/1036C interact with one
another to refine a
significant number of the wood fibers in the wood pulp. When the fibers pass
into the portion of
the refining space that is at least partially defined by the second and fourth
refiner grooves
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1028B'/1038B' and 1028D/1038D (e.g., first and second deflaking zones, as
described above), the
intensity of the force applied to the fibers decreases in response to the
reduced height, which is
believed to break up or separate a plurality of the wood fiber bundles formed
during refining
without further refining or only minimally refining the fibers.
In this example, the gap between opposing portions of the second refiner bars
1026W,
1036B' and between opposing portions of the fourth refiner bars 1026D, 1036D
may be from about
0.9 mm to about 20.0 mm 0.05 mm). This range includes all values and subranges
therebetween,
including, for example, 0.9, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5,
6.0, 6.5, 7.0, 7.5, 8.0, 8.5,
9.0,9.5, 10.0, 10.5, 11.0, 11.5, 12.0, 12.5, 13.0, 13.5, 14.0, 14.5, 15.0,
15.5, 16.0, 16,5, 17.0, 17.5,
18.0, 18.5, 19.0, 19.5, and 20.0 mm. In examples in which one or more of the
second and fourth
refiner bars 1026B'/1036B' and 10260/1036D slope substantially continuously
downward along
at least a portion, the gap may increase along at least a section of the
second refiner bar 1026W,
1036B' in a radially outward direction, i.e., in a direction extending from
the second radially
inward position (e.g., P200cr) to the second radially outward position P3oom
of the second refiner
bars 1026B', 1036B', and/or the gap may increase along at least a section of
the fourth refiner bar
1026D, 1036D in a radially outward direction, i.e., in a direction extending
from the fourth radially
inward position (e.g., Pa000) to the fourth radially outward position Ps000 of
the fourth refiner bars
1026D, 1036D. In some examples, the gap may increase along substantially an
entirety of the
longitudinal length Limo' and/or L2000 of the second and/or fourth refiner
bars 1026B71036B' and
1026D/1036D, respectively. In order to cease refining of the fibers and begin
deflaking, it is
believed that the second (minimum) height 1-1.200cr of the second refiner bars
1026B', 1036W and
the fourth (minimum) height H4000 of the fourth refiner bars 1026D, 1036D
should be at least about
0.35 mm ( 0.05 mm) less than the first height thaw of the first refiner bars
1026A', 1036A' and
the third height H3000 of the third refiner bars 1026C, 1036C, respectively.
In other examples, one of the refining bodies 1022', 1032' shown in FIG. 19B
may be
paired with a conventional refining body (not shown; see 132 in FIG. 8) that
comprises refiner
bars with a uniform height along substantially an entirety of their
longitudinal length. For instance,
the first refining member 20 may comprise the first refining body 1022', and
the second refining
member 30 may comprise the conventional refining body. The refining members
20, 30 may be
arranged such that they face each other, with at least a portion of the first,
second, third, and fourth
refiner bars 1026A', 1026B', 1026C, 1026D being positioned so as to be across
from, i.e., facing,
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at least a portion of the conventional refiner bars to define a gap (see FIGS.
8 and 9) between the
opposing portions. As described herein, a slurry of wood pulp is supplied, and
an axial force or
pressure may be applied to one or both of the refining members 20, 30 to
adjust the size of the gap,
with the first and third refiner bars 1026K, 1026C being adapted to refine the
wood fibers in the
pulp slurry and the second and fourth refiner bars 1026B', 1026D being adapted
to break up or
separate fiber bundles. In this example, the gap between opposing portions of
the conventional
refiner bars and the second and fourth refiner bars 1026W, 1026D may be from
about 0.9 mm to
about 10.0 min ( 0.05 mm). This range includes all values and subranges
therebetween,
including, for example, 0.9, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5,
6.0, 6.5, 7.0, 7.5, 8.0, 8.5,
9.0, 9.5, and 10.0 mm. In embodiments in which the second and/or fourth
refiner bars 1026B',
1026D slope, the gap may increase along at least a section of the refiner bars
1026B', 1026D in a
radially outward direction, as described herein, and may increase along
substantially an entirety of
the longitudinal length Lwow, L2000 of the second and/or fourth refiner bars
1026B', 1026D. In this
example, it is believed that the second (minimum) height Hnoir of the second
refiner bars
1026B '/1036B' and the fourth (minimum) height Moo of the fourth refiner bars
10261)/103613
should be at least about 0.7 min ( 0.05 mm) less than the first height 1-
Iwoo' of the first refiner bars
1026A71036A' and the third height H3000 of the third refiner bars 1026C,
1036C, respectively, in
order to cease refining of the fibers and begin deflaking.
In both examples, it is believed that the gap between opposing portions of the
refiner bars
should be less than about 0.9 mm (+ 0.05 mm) in order for refining to occur
(e.g., between opposing
portions of the first and third refiner bars 1026A', 1036K and 1026C, 1036C or
between opposing
portions of the conventional refiner bars and the first and third refiner bars
1026A'/1036A' and
1026C/1036C). In some instances, the gap in the refining zone(s) may be less
than about 0.7 mm
( 0.05 mm). In some particular instances, the gap may be from about 0.1 mm to
about 0.5 mm
( 0.05 mm). This range includes all values and subranges therebetween,
including, for example,
0.1, 0.15, 0.2, 0.25, 0.3, 0.35, 0.4, 0.45, and 0.5 mm. It is also believed
that the gap should be from
about 0.9 mm to about 2.0 mm ( 0.05 mm) in order for deflaking to occur
(e.g., between opposing
portions of the second and fourth refiner bars 10268', 103614' and 1026D,
10361) or between
opposing portions of the conventional refiner bars and the second and fourth
refiner bars
1026B'/1036B' and 1026D/1036D). This range includes all values and subranges
therebetween,
including, for example, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9,
and 2.0 mm. As described
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herein, a gap larger than about 2A) nun may be used to account for wear that
reduces the heights
Htoocr, H2000', H3000, Mow of the respective refiner bars 1026A', 1036A',
1026B', 1036W, 1026C,
1036C, 1026D, 1036D. The position of the refining bodies may be adjusted as
described herein
to maintain the gap at a desired value as the refining surfaces begin to wear
down. In particular,
embodiments in which the second and/or fourth refiner bars 1026B71036W and
1026D/1036D
slope substantially continuously downward along at least a portion of the
refiner bar
1026B'/1036B' and 1026D/1036D are believed to allow the transition between the
refining and
deflaking zones to shift radially outward along the longitudinal length Limo',
Lz000 of the second
and/or fourth refiner bars 1026B'/103611' and 1026D/1036D, such that a gap of
about 0.9 mm to
about 2.0 mm for deflaking may be maintained throughout the life of the
refining members.
FIGS. 13 and 14 are plan views of portions of a first refining surface 224 of
a first refining
body 222 and a second refining surface 234 of a second refining body 232,
respectively, according
to another embodiment of the present disclosure. With reference to FIGS. 1,
13, and 14, the first
and second refining bodies 222, 232 may be part of refining members, e.g.,
refining members 20,
30, respectively, as described herein, for use in a pulp refiner, such as the
disc refiner 10 depicted
in FIG. 1. Each of the refining members 20, 30 comprising the first and second
refining bodies
222, 232, respectively, may be associated with the main support frame
comprising the fixed
support frame 66 secured to the first housing section 12 and the movable
support frame 68. One
refining member, e.g., the first refining member 20 comprising the first
refining body 222, may be
fixed to the support frame 66 of the refiner 10 to define a non-rotating
stator member. Another
refining member, e.g., the second refining member 30 comprising the second
refining body 232,
may be fixed to the support 70, which rotates with the shaft 72 and defines a
rotor that is associated
with the main support frame, such that rotation of the rotor effects movement
of the second refining
member 30 relative to the first refining member 20.
As shown in FIG. 13, the first refining body 222 comprises a plurality of
sections (not
separately labeled; see FIGS. 2 and 3) that may be bolted or otherwise
attached together to form
the disc-shaped refining body 222 comprising a radially outer edge 227. The
first refining surface
224 comprises a plurality of elongated first refiner bars 226 separated from
one another by first
refiner grooves 228. The first refiner bars 226 extend radially outwardly from
a radially inner
location 223 toward the radially outer edge 227 of the first refining body
222. The first refiner
bars 226 may be slanted at various angles as shown in FIG. 13, and each
section of the refining
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body 222 may comprise one or more segments (not labeled) of refiner bars 226
that are slanted in
different directions. The first refining body 222 further comprises one or
more annular rows or
rings of teeth 400 located between the first refiner bars 226 and the radially
outer edge 227 of the
first refining body 222. Although not shown in FIG. 13, it is understood that
the other sections
(not labeled) of the first refining body 222 would similarly comprise refiner
bars 226, refiner
grooves 228, and teeth 400.
As shown in FIG. 14, the second refining body 232 comprises a plurality of
sections (not
separately labeled; see FIGS. 2 and 3) that may be bolted or otherwise
attached together to form
the disc-shaped refining body 232 comprising a radially outer edge 237. The
second refining
surface 234 comprises a plurality of elongated second refiner bars 236
separated from one another
by second refiner grooves 238. The second refiner bars 236 extend radially
outwardly from a
radially inner location 233 toward the radially outer edge 237 of the second
refining body 232,
The second refiner bars 236 may be slanted at various angles as shown in FIG.
14, and each section
of the refining body 232 may comprise one or more segments (not labeled) of
refiner bars 236 that
are slanted in different directions. The second refining body 232 further
comprises one or more
annular rows or rings of teeth 400 located between the second refiner bars 236
and the radially
outer edge 237 of the second refining body 232. Although not shown in FIG. 14,
it is understood
that the other sections (not labeled) of the second refining body 232 would
similarly comprise
refiner bars 236, refiner grooves 238, and teeth 400. In addition, although
not discussed in detail
herein, the structure of the refining surfaces 44, 54 of the third and fourth
refining bodies 42, 52,
respectively, of FIG. 1 may comprise a structure that is substantially similar
to the refining surfaces
224, 234 of the first and second refining bodies 222, 232, respectively, as
described herein.
FIGS. 15 and 16 are detailed views of one portion of the first and second
refining surfaces
224, 234, of FIGS. 13 and 14, respectively. FIG. 17 is a partial cross-
sectional view of a first
refiner bar 226 and tooth 400B, which may be located on the first refining
body 222 of FIGS. 13
and 15, and a second refiner bar 236 and teeth 400A, 400C, which may be
located on the second
refining body 232 of FIGS. 14 and 16, in which the first refining body 222 is
spaced apart and
positioned adjacent to and across from the second refining body 232 to define
a refining space 260
therebetween. With reference to FIGS. 15-17, the first refining surface 224
comprises first refiner
bars 226 that are separated from one another by first refiner grooves 228, and
the second refining
surface 234 comprises second refiner bars 236 that are separated from one
another by second
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refiner grooves 238. One or both of the first and second refining surfaces
224, 234 may comprise
dams 229, 239 provided in at least a portion of the first and second refiner
grooves 228, 238, as
described herein. Each of the first and second refiner bars 226, 236 extends
from a radially inward
position 13100 to a first radially outward position P200 on the respective
first and second refining
surfaces 224, 234. In some examples, the radially inward position Proo may
comprise a position
at or near the respective radially inner location 223, 233 (see FIGS. 13 and
14). The first and
second refiner bars 226, 236 may comprise a width W226, W236, respectively,
extending between
sides edges of the respective refiner bars 226, 236 of from about 2.0 mm to
about 8.0 mm. This
range includes all values and subranges therebetween, including, for example,
2.0, 2.5, 3.0, 3.5,
4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, and 8.0 mm.
The first refining surface 224 comprises first teeth 400B located between a
radially outer
edge R0226 of the first refiner bars 226 and the radially outer edge 227 of
the first refining body
222. The first teeth 400B extend to a third radially outward position, e.g.,
P400, on the first refining
surface 224, in which the third radially outward position Poo is nearer to an
outermost part, e.g.,
the radially outer edge 227, of the first refining body 222 than the first
radially outward position
P200 of the first refining bars 226. The second refining surface 234 comprises
second teeth 400A,
400C that are located between a radially outer edge R0236 of the second
refiner bars 236 and the
radially outer edge 237 of the second refining body 232. The second teeth
400A, 400C extend to
a second or a fourth radially outward position, e.g., P300 or Psoo, on the
second refining surface 234,
in which the second and fourth radially outward positions P300, Psoo are
nearer to an outermost part,
e.g., the radially outer edge 237, of the second refining body 232 than the
first radially outward
position P200 of the second refining bars 236.
With continued reference to FIGS. 15-17, the teeth 400A-400C may be arranged
in
concentric rings and may protrude substantially perpendicularly toward one
another from the
respective refining surfaces 224, 234. The ring comprising first teeth 400B is
spaced apart from
the radially outer edge R0226 of the first refiner bars 226 by a first
substantially planar area 282
and from the radially outer edge 227 of the refining body 222 by a second
substantially planar area
284. The ring comprising second teeth 400A is spaced apart from the radially
outer edge R0236
of the second refiner bars 236 by a first substantially planar area 286 and
from the ring comprising
second teeth 400C by a second substantially planar area 288. In the embodiment
shown in FIGS.
15-17, the first refining surface 224 of the first refining body 222 comprises
one concentric
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row/ring of first teeth 400B, and the second refining surface 234 of the
second refining body 232
comprises two concentric rows/rings of second teeth 400A, 400C, in which the
first and second
teeth 400A-400C are arranged on the respective refining surfaces 224,234 such
that the first teeth
400B intermesh with the second teeth 400A, 400C. In other embodiments (not
shown), the first
refining surface 224 may comprise two or more concentric rings of teeth, and
the second refining
surface 234 may comprise one concentric row of teeth or three or more
concentric rings of teeth.
In all embodiments, one of the refining bodies will comprise one fewer rings
of teeth than the other
refining body, and the teeth are arranged on each refining body such that the
teeth from one refining
body intermesh with the teeth of the other refining body, as is known in the
art.
It is understood that the teeth 400A-400C may comprise any suitable shape
and/or
dimensions known in the art. As illustrated with respect to tooth 400A in FIG.
17, in some
examples, each of the first and second teeth 400A-400C may comprise a
substantially pyramidal
or trapezoidal shape with a base 402, a radially inward facing surface 404, a
radially outward
facing surface 406, sides (not separately labeled) slightly angled inwardly
toward a center axis (not
labeled) of the tooth 400A, and a generally planar outer surface 408. The
radially inward and
outward facing surfaces 404, 406 of each tooth 400A-400C may slope from the
base 402 towards
its respective outer surface 408 The outer surface 408 of each tooth 400A-400C
may be
substantially parallel to a plane of the respective substantially planar area
282, 284, 288 that is
opposite the tooth 400A-400C. In other examples (not shown), each of the first
and second teeth
400A-400C may comprise a shape that is substantially triangular, rectangular,
or any other suitable
geometric shape. As shown in FIGS. 15-17, the base 402 of the teeth 400A-400C
may comprise
a radial dimension that is greater than a circumferential dimension, but in
other embodiments (not
shown), the base 402 may comprise a radial dimension that is less than a
circumferential
dimension. In some instances, at least a portion of the base 402 of teeth 400A-
400C may comprise
a longitudinal length (not labeled), i.e., in a radial direction, of at least
0.6 cm, and in some
particular instances, the longitudinal length may comprise between 0.6 cm to
about 2 cm. In other
instances, at least a portion of the base 402 of the teeth 400A-400C may
comprise a width (not
labeled), in a circumferential direction, that is substantially equal to the
combined width, e.g., W226,
W236, of one refiner bar 226,236 and a width Woof one adjacent groove 228,
238. The width WG
may be from about 2.0 mm to about 6.0 mm. This range includes all values and
subranges
therebetween, including, for example, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5,
and 6.0 mm. For
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example, the base 402 of the teeth 400A-400C may comprise at least about 10.0
mm ( 0.5 mm)
in the circumferential direction. In other instances, the base 402 of the
teeth 400A-400C may
comprise from about 10.0 mm to about 20.0 mm 0.5 mm) in the circumferential
direction. In
addition, one or more of the radially inward and outward facing surfaces 404,
406 or the sides of
one or more of the teeth 400A-400C may comprise one or more radially-extending
projections that
may affect the interaction of the teeth 400A-400C with the wood fibers to
separate wood fiber
bundles. The teeth 400A-400C may have a structure similar to those illustrated
in U.S. Patent No.
8,342,437 B2, the disclosure of which is incorporated herein by reference.
As shown in FIG. 17, the first refiner bars 226 comprise a first height Hi
extending
upward from a floor Ftoo of an adjacent first refiner groove 228, and the
second refiner bars 236
comprise a second height H2oo extending upward from a floor F200 of an
adjacent second refiner
groove 238. In some examples, the first and second heights H100, H200 of the
first and second
refiner bars 226, 236 may be substantially equal to one another and may
comprise from about 4.0
mm to about 10.0 mm 0.5 mm). This range includes all values and subranges
therebetween,
including, for example, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, 8.0, 8.5, 9.0,
9.5, and 10.0 mm. The
first and second refining bodies 222,232 are spaced apart by a first gap Gtoo
that is defined between
an outer surface S226 of the first refiner bar 226 and an outer surface S236
of the second refiner bar
236. A second gap G200 is defined between the generally planar outer surfaces
408 of the teeth
400A-400C and a respective one of the substantially planar areas 282, 284, 288
that is opposite
the tooth 400A-400C, in which G200 may be greater than Gioo. In some examples,
a height (not
labeled) of the teeth 400A-400C extending upward from the adjacent, respective
first or second
refiner groove 228, 238 may be from about 8.0 mm to about 10.0 mm. This range
includes all
values and subranges therebetween, including, for example, 8.0, 8.5, 9.0, 9.5,
and 10.0 mm. As
shown in FIG. 17, the teeth 400A-400C are intermeshed such that a portion of
one or both of the
radially inward or outward facing surfaces 404, 406 of each tooth 400A-400C
overlaps in an axial
direction, e.g., in the direction of arrow A in FIG. 1, with a portion of the
radially inward or outward
facing surface 404, 406 of an adjacent tooth 400A-400C. The overlapping
portion(s) of the teeth
400A-400C may be spaced apart by a third gap G300 that is defined between the
respective radially
inward or outward facing surfaces 404,406 of the teeth 400A-400C. In some
examples, G300 may
be substantially equal to G200. In other examples, G300 may be less than or
more than G200.
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With reference to FIGS. 1 and 17, when a slurry of wood pulp is supplied to
the frame of
the refiner 10, e.g., the inlet 16, the wood fibers pass into the portion of
the refining space 260 that
is at least partially defined by the first and second refiner grooves 228,
238, e.g., from about the
first radially inward position Pioo to about the first radially outward
position P200. The first and
second refiner bars 226, 236 interact with one another to refine a significant
number of the wood
fibers in the wood pulp, as described herein. It is believed that the first
gap Gtoo should be less
than about 0.9 min (th 0.05 mm) and preferably from about 0.2 mm to about 0.9
mm (th 0.05 mm)
in order for refining to occur. This range includes all values and subranges
therebetween,
including, for example, 0.2, 0.25, 0.3, 0.35, 0.4, 0.45, 0.5, 0.55, 0.6, 0.65,
0.7, 0.75, 0.8, 0.85, and
0.9 mm. In some examples, the first gap Gioo may be from about 0.1 mm to about
0.5 mm (th 0.05
mm), This range includes all values and subranges therebetween, including, for
example, 0,1,
0.15, 0,2, 0,25, 0,3, 0.35, 0.4, 0,45, and 0.5 mm. The refined wood fibers
then pass into the portion
of the refining space 260 that is at least partially defined by the respective
first and second
substantially planar areas 282, 284, 286, 288, e.g., from about the first
radially outward position
Pme to about the fourth radially outward position P500. It is believed that
the second and third gaps
Groo and G300 should be from about 0,9 mm to about 1.5 min (th 0.05 mm) in
order for deflaking to
occur. This range includes all values and subranges therebetween, including,
for example, 0.9,
0.95, 1.0, 1,05, 1.1, 1.15, 1.2, 1.25, 1.3, 1,35, 1.4, 1.45, and 1.5 mm. The
teeth 400A-400C are
adapted to break up or separate a plurality of wood fiber bundles in the wood
pulp slurry, as
described herein. G200 is greater than Gioo such that it is believed that
refining stops and deflaking
begins at about the first radially outward first position P200.
With reference to FIGS. 1 and 15-17, the refining surfaces 224, 234 of the
refining bodies
222, 232, particularly the outer surfaces S226, S236 of the first and second
refiner bars 226, 236 and
the outer surfaces 408 of the teeth 400A-400C, may wear and degrade over time.
To compensate
for this wear, the spacing between the first and second refining members 20,
30 comprising the
first and second refining bodies 222, 232, respectively, may be readjusted as
described herein such
that the first gap Gioo remains substantially constant. This adjustment of the
first and second
refining bodies 222, 232 may cause the second gap G200 to decrease, as the
refiner bars 226, 236
perform the more intense function of refining and typically wear faster than
the teeth 400A-400C.
This difference in wear may be factored into the selection of the teeth 400A-
400C (e.g., the type(s)
of metal used for the teeth 400A-400C, the initial size of the second gap
Groo, the shape of the
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teeth 400A-400C, etc.) such that an adequate second gap G200 may be maintained
to ensure that
refining ceases and deflaking begins when the wood fibers enter the portion of
the refining space
260 that is at least partially defined by the respective first and second
substantially planar areas
282, 284, 286, 288. When the refining bodies 222, 232 are new, the third gap
6300 may be
substantially equal to or greater than the second gap thoo. As the refining
surfaces 224, 234 wear
and the refining members 20, 30 are moved closer together, the third gap G300
may decrease until
the third gap G3ocp is less than the second gap G200.
In all embodiments described herein, the refiner 10 of FIG. 1 may be coupled
to a controller
(not shown) that receives data from a fiber analyzer (e.g., a Valmet MAP Pulp
Analyzer (Valmet
Corp.)) regarding one or more fiber properties measured at one or more
locations downstream of
the refiner 10, such as a number, size, etc. of fiber bundles (also referred
to as "Wide Skives"),
fibrillation, Canadian Standard Freeness, fiber length, fiber width, kink,
cud, coarseness, number
of fines, etc. Based on this data, the controller may control operation of the
refiner 10 as part of a
feedback loop. For example, the controller may adjust the spacing between the
one or more pairs
of refining members 20, 30, 40, 50 in order to maintain the one or more fiber
properties within a
predetermined target range. In some examples, it is believed that the
controller may also increase
or decrease a rotational speed of the one or more rotating rotor members of
the refiner 10 (e.g., the
second and third refining members 30, 40) based on this data. In other
examples, the controller
may control operation of the refiner 10, such as by varying the size of the
refining gap GI, Gtoo,
and the deflaking gap G2, G3, G4, Gs, 66, thoo, 6300, to generate a refined
softwood pulp that has
less than a predetermined number, e.g., 1,000 ppm, of fiber bundles of a
particular size, e.g., about
150 -2,000 microns wide and from 0.3 to 40,0 mm long.
In other examples, refining members 20, 30, 40, 50 according to the present
disclosure may
be installed in one or more of a plurality of refiners that are arranged in a
series, in which each
refiner may be substantially similar to the refiner 10 of FIG. 1. The
controller may control
operation of one or more of the plurality of refiners in order to maintain the
one or more fiber
properties within the predetermined target range. In some particular examples,
refining members
20, 30, 40, 50 according to the present disclosure may be installed only in
the last refiner of the
series, and in other examples, refining members 20, 30, 40, 50 according to
the present disclosure
may be installed in two or more of the refiners.
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FIG. 18 is a flowchart illustrating an exemplary method for processing wood
fibers.
Although reference is made to the components of the refiner 10 in FIG. 1, it
is understood that the
method is not limited only to this structure. The method may begin at Step 500
with providing a
refiner 10 comprising at least a first pair of refining members 20 and 30, 40
and 50 The at least
one pair of refining members may comprise a first refining member 20
comprising a first refining
body 22 including a first refining surface 24 and a second refining member 30
comprising a second
refining body 32 including a second refining surface 34. The first refining
surface 24 may
comprise first refiner bars 26A separated by first refiner grooves 28A and
second refiner bars 26B
separated by second refiner grooves 28B, in which the first refiner bars 26A
have a first maximum
height Hi extending upward from a floor Ft of an adjacent first refiner groove
28A and the second
refiner bars 26B having a second maximum height H2 extending upward from a
floor F2 of an
adjacent second refiner groove 28B. The second refining surface 34 may
comprise second member
refiner bars 36 separated by second member refiner grooves 38. The first
refining member 20 may
be spaced from the second refining member 30 to define a refining space 60
therebetween. At
least a portion of the second member refiner bars 36 may be positioned so as
to be across from the
second refiner bars 2611 of the first refining member 20 such that a gap G2,
63, G4, 65, G6 between
the portion of the second member refiner bars 36 and the second refiner bars
2611 is defined.
The method may continue with rotating at least one of the first refining
member 20 or the
second refining member 30 such that the first and second refining members 20,
30 move relative
to one another in Step 510, and supplying a slurry of wood pulp comprising
wood fibers to the
refiner 10 such that the slurry passes through the refining space 60 in Step
520, At Step 530, axial
pressure may be supplied to at least one of the first refining member 20 or
the second refining
member 30 as the slurry is supplied such that the gap G2, G3, G-4, 65, G6
between the portion of the
second member refiner bars 36 and the second refiner bars 26B is from about
0.9 mm to about 1.5
mm as described in detail herein, in which at least a portion of wood fiber
bundles passing through
the gap G2, (13 , G4, G5, G6 are separated, after which the method may
terminate.
FIG. 20 is a flowchart illustrating another exemplary method for processing
wood fibers.
Although reference is made to the components of the refiner 10 in FIG. 1, it
is understood that the
method is not limited only to this structure. For example, the refiner may
comprise a conical
refiner. The method may begin at Step 600 with providing a refiner 10
comprising at least a first
pair of refining members 20 and 30, 40 and 50. The at least one pair of
refining members may
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comprise a first refining member 20 comprising a first refining body including
a first refining
surface. The first refining surface may comprise first refiner bars, e.g.,
refiner bars 26A, 26K,
1026A, 1026A' in FIGS. 6A, 6B, 19A, and 19B, separated by first refiner
grooves and second
refiner bars, e.g., refiner bars 26B, 26W, 1026B, 1026W in FIGS. 6A, 6B, 19A,
and 19B, separated
by second refiner grooves, in which the first refiner bars have a first height
extending upward from
a floor of an adjacent first refiner groove and the second refiner bars having
a second height
extending upward from a floor of an adjacent second refiner groove. The at
least one pair of
refining members may further comprise a second refining member 30 comprising a
second refining
body including a second refining surface. The second refining surface may
comprise second
member refiner bars, e.g., refiner bars 36, 36', 1036, 1036' in FIGS. 6A, 6B,
19A, and 19B,
separated by second member refiner grooves. The first refining member 20 may
be spaced from
the second refining member 30 to define a refining space 60 therebetween. At
least a portion of
the second member refiner bars may be positioned so as to be across from the
second refiner bars
of the first refining member to define a gap between the portion of the second
member refiner bars
and the second refiner bars.
The method may continue with rotating at least one of the first refining
member 20 or the
second refining member 30 such that the first and second refining members 20,
30 move relative
to one another in Step 610, and supplying a slurry of wood pulp comprising
wood fibers to the
refiner 10 such that the slurry passes through the refining space 60 in Step
620. At Step 630, axial
pressure may be supplied to at least one of the first refining member 20 or
the second refining
member 30 as the slurry is supplied in which at least a portion of wood fiber
bundles passing
through the gap are separated, after which the method may terminate. The gap
defined between
the portion of the second member refiner bars and the second refiner bars may
increase along at
least a section of the second refiner bars in a direction extending from a
first radially inward
position toward a first radially outward position on the first refining
surface.
While particular embodiments of the present invention have been illustrated
and described,
it should be understood that various changes and modifications may be made
without departing
from the spirit and scope of the invention. It is therefore intended to cover
in the appended claims
all such changes and modifications that are within the scope of this
invention.
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