NZ624261B - Reduced mass plates for refiners and dispersers - Google Patents

Abstract

light weight plate segment (200) configured to be mounted on a disc of a disperser or refiner for comminuted cellulosic material including: a front face having disperser teeth or refining bars; a back face (205) having a raised post (260) surrounding a fastener attachment structure (220) and a raised plate positioning section (210); side edges of the plate segment; and a radially outer edge and a radially inner edge extending between the side edges. The back face lacks raised structures along the side edges. sed plate positioning section (210); side edges of the plate segment; and a radially outer edge and a radially inner edge extending between the side edges. The back face lacks raised structures along the side edges.

Description

REDUCED MASS PLATES FOR REFINERS AND DISPERSERS RELATED APPLICATION This application claims priority and incorporates by reference U. S. provisional application serial number 61/823,566 filed May 15, 2013.

TECHNICAL FIELD The disclosure relates to plates and plate segments for refiners and dispersers (also known as dispergers) used in ical pulping and paper recycling ses to produce pulp material and recycled pulp material for various end uses.

BACKGROUND OF THE INVENTION In the production of pulp material to be used in the making of paper or other paper based packaging material. One conventional method is to employ a ical refiner. Mechanical refiners include, but are not limited to, refiners to process comminuted cellulosic material such as wood chips, etc. to produce pulp, and dispersers typically used in the processing of ed paper al. Mechanical refiners typically include a set of opposing discs, such as a pair of flat discs at least one of which rotates, a pair of conically shaped discs, and an assembly of parallel flat and conical discs. As feed al moves through a gap between the opposing discs, fibers in the al are separated to produce refined pulp; ink, and other contaminates may be dispersed from paper to produced a recycle pulp material.

Mechanical refiners that produce pulp from wood chips and other comminuted cellulosic material, typically referred to as refiners, have plates with bars and grooves on the front face of their plates. The plates are mounted on opposing discs. The gap between plates with bars and grooves is typically planer and formed between the upper ridges of the bars on ng plates. Mechanical refiners used to process recycled paper and paperboard material are typically referred to as dispergers or dispersers, and have plates with teeth on the front face of the plates. The gap n opposing plates in a disperser may have a serpentine shape formed by the eshing rows of teeth on the opposing front faces of the .

The refining or dispersing action occurs as feed material, e.g., wood chips or recycled paper, enters the gap between the discs through an opening in one of the plates. The feed material is driven by centrifugal force to move radially outwardly through the gap and between the front faces of the plates.

The refining or dispersing surfaces on the front faces act on the feed material as the material moves through the gap and is subjected to pulsating forces due to the ng of the bars or teeth on the plates.

Plates may be formed by an r assembly of plate segments mounted on the discs. The plates are generally an annular array of plate segments, such as pie shaped segments. The segments are mounted side- by-side to form a circular plate mounted onto the disc mounting surface. The plates have a front face with bars and grooves forming refining surfaces in a pulp refiner or rows of teeth forming dispersing surfaces in a disperser. The gap in the refiner or disperser is formed n the front faces of the plates on the opposing discs. The back faces of the plates are mounted to a disc mounting surface. Bolts and other fasteners hold the plates to the disc mounting surface.

Plate segments, for a convention mechanical refiner (capable of handling high, medium or low tency feed material) or a disperser (capable of handling recycled material feed material), are a critical component of the refining or dispersing equipment. As the feed material moves across the surface of the plate segments, the surface of the fronts of the plate segments wear down. The refining and dispersion action med by the plate segments become less effective as the plates wear down. The worn plate segments must be replaced. Generally, plate segments are periodically replaced on refiners and dispersers.

A l annular array of plate segments for a refiner or disperser es three (3) to twenty four (24) equally-sized plate segments. At every plate change, all segments of an annular array of plate segments are d and inspected, mounting surface (surface of the discs) cleaned, and the new segments installed. The plate segments that can be re used are cleaned and new segments are substituted for worn ts, typically all plate segments are replaced but there are times when some plate segments may be cleaned and reused. The d and new segments are mounted one-by-one onto the disc mounting surface. T he mounting of each segment requires a shimming process to maintain equal spacing between the segments. The mounting also involves applying a proper torque to the fastener securing the segments to the disc mounting surface.

Refiners and dispersers usually have two annular plates arranged opposite to each other in the refiner. In the twin refiners or twin dispersers, there may be four plates arranged in two opposing pairs of plates. The refiner or disperser may have one rotor (which may be a double-sided rotor in a twin refiner or disperser) facing a stationary stator. Alternatively, the refiner or disperser may have opposite counter-rotating rotors. Regardless of the specific disc configuration, the plate segments mounted to the discs are periodically ed. Plate t replacement is needed because the refining or dispersing surface on the segments wears down by the veness of the feed material rubbing t these surfaces. A worn refining or dispersing surface reduces the ency of the refiner or disperser.

Plate segments generally must be rigid and structurally strong. The plate ts must support the front faces that se many bars and grooves for refiners and teeth for dispersers, which are subjected to uous refining or dispersing action of the ve feed material as they encounter the feed material, centrifugal forces in the refiner or disperser, and stresses from the ers, e.g., bolts, that affix the segments to the disc ng surface. A minimum plate thickness is conventionally in a range of 1.0 to 1.5 inches (25 to 38 millimeters (mm)). Additionally, the back face of the plate segments conventionally have a network of raised ribs, posts surrounding the bolt holes and other raised structures to provide structural support to the segments and to provide abutments that seat against the disc mounting surface.

The thickness requirement and k of raised structures on the plate ts contribute substantially to the mass of the segments. The segments are formed by casting molding metal. The cast plate segments tend to have a large mass (i.e., heavy in weight), which makes the cast plate segments difficult to handle when replacement is necessary. The large mass of the plate segments increases the cost of casting due to the cost for a large amount of metal, cost of shipping and cost to handle and mount the segments to the disc. It is desirable to produce a plate segment using a less amount of metal while meeting the mounting and structural requirements needed for a urally strong and rigid segment.

BRIEF DESCRIPTION OF THE INVENTION In a first aspect, the present invention provides a plate segment configured to be mounted on a disc of a ser or refiner of comminuted cellulosic material, the t comprises: a front face of a plate segment including disperser teeth or refining bars; a back face of a plate segment on an opposing major surface to the front face, including a raised post surrounding a fastener ment ure and a raised plate positioning section; side edges of the plate segment located along edges of the front face and the back face; and a radially outer edge and a radially inner edge extending between the side edges; wherein the back face lacks raised structures along the side edges.

In a second aspect, the present ion provides an assembly of a disc and a plate segment for a refiner or disperser comprising: a plate segment including a front face having disperser teeth or refining bars, a back face having a raised post surrounding a er attachment structure and a raised plate positioning section; side edges located along edges of the front face and back face, and a radially outer edge and a radially inner edge extending between the side edges, wherein the back face lacks raised structures along the side edges; and a disc having a disc mounting surface configured to mount the plate segment, the disc mounting surface abuts the post and plate positioning section of the plate segment.

In a third aspect, the present invention provides a plate segment comprising: a front face on a plate segment, including disperser teeth or refining bars; a back face on a major surface of the plate segment opposing the front face, including a raised post surrounding a er attachment structure and a raised plate positioning section; side edges of the plate segment d along edges of the front face and the back face; a radially outer edge and a ly inner edge extending between the side edges; and a grooved space on the back face and nt to the radially inner edge, the grooved space is configured to receive a seal; wherein the back face lacks raised structures along the side edges.

According to some embodiments of the present invention, a plate segment useful for mechanical refiner plate ts and disperser plate segments has been conceived having a reduced mass (i.e., lighter in ).

The reduction of mass is achieved by minimizing the network of raised ribs and other raised structures on the back face (non-grinder and refining surface) of a tional plate segment. The novel light weight plate segment has sufficient th to support the grinding and refining surfaces on the front of the segment without unduly increasing the risk that the segment will break.

The novel plate segment may lack conventional ribs along the edges of the segment, outer diameter (OD) ribs (also referred to as support material), and many (but not all) of the conventional reinforcement ribs or support material. Minimizing the network of raised ribs and other structures reduces the weight of the plate segment by 20 to 40 t, as compared to conventional plate segments. Using the invention disclosed herein, the network of ribs and other raised structures on the back face of a plate segment may be achieved without adversely affecting the structural integrity and rigidity of the plate segments.

A novel plate segment has been conceived that is configured to be mounted on a disc of a disperser or refiner for comminuted osic material, the segment comprises: a front face including ser teeth or refining bars; a back face including a raised post surrounding a fastener attachment ure and a raised plate positioning n, and side edges; extending between the side edges are both a radially outer edge and a radially inner edge; wherein the back face lacks raised structures along the side edges.

BRIEF DESCRIPTION OF THE DRAWINGS is a perspective view of a back face of a conventional plate segment suitable for a r or disperser, wherein the back face includes a network of raised ribs and other raised structures. is a ctive view of a back face of a novel plate segment suitable for a refiner or disperser, wherein the back face lacks the raised ribs shown in and has raised bolt hole posts and plate positioning ribs aligned with the posts. is a perspective view of r novel plate segment including a ring-section along an inner edge of the segment. is a cross-sectional side view of the novel plate segment with a ring-section separated from an inner edge section d by line A-A. is a cross-sectional side view of a first embodiment of the ringsection and the inner edge section. is a cross-sectional side view of a second embodiment of the ring-section and the inner edge section, wherein a groove space on the inner edge faces a groove space on the ring-section. is a cross-sectional side view of a third embodiment of the ringsection and the inner edge section, wherein the ring-section and the inner edge section have abutting d surfaces. is a cross-sectional side view of a fourth ment of the ringsection and the inner edge section, n the ring-section and the inner edge section have abutting slanted surfaces. is a cross-sectional side view of another embodiment of the novel plate segment with an inner edge section defined by line circle B. is a cross-sectional side view of the inner edge section shown in Figure 9 abutting a disc mounting surface. is a ctive view of another embodiment of the novel plate segment including a ring n along the inner edge of the segment. is a side view of opposing plate segments each mounted to a disc mounting surface. is a flow chart of a method of forming a plate segment.

DETAILED DESCRIPTION OF THE INVENTION It is desirable to provide a refiner or disperser plate segment with mass (i.e., weight) removed from the back face of the plate (i.e., the side adjacent the surface of the disc) while maintaining the strength required to provide refining or dispersing actions without structural damage to the plate segments. shows the back face for a conventional plate segment 100. A k of ribs 110 and other raised areas are formed on the back face. The k includes raised posts 118 surrounding bolt holes 120, the edge ribs 140 along the ly outer edge of the plate segment, interior ribs and raised ures 135, and a ring segment 130 of a ring at the radially inward edge of the segment. The network of ribs 110 is ed to e structural support and rigidity to the conventional plate segment, to reduce the risk that segment will break, and to provide support surfaces that abut against the mounting surface of a disc.

The intended functions served by the network of ribs 110 support the conventional wisdom that such a k is needed on a plate segment. The inventors of the light weight plate segments disclosed herein broke from conventional wisdom. The inventors realized that the conventional network of ribs and other raised areas could be replaced by a reduced arrangement of support posts for each bolt hole and a supporting strip associated with each post.

The back face of a novel plate segment that has reduced mass includes raised posts and raised plate positioning sections. Each raised post surrounds one of the bolt holes and has a mounting surface seated against a disc mounting surface. The raised plate positioning sections are also mounting surfaces that seat against the disc mounting e. The posts and plate positioning sections provide sufficient mounting surfaces to support the plate segment on the disc ng surface. They also provide structural support to the plate segment.

The posts and the plate positioning sections fix the position of the plate segment with respect to the plate segment. The posts and plate positioning sections may have the only surfaces on the plate segment that abuts the disc mounting surface. An inner ring segment (arc-edge) on the plate segment may also abut the disc mounting e and fix the plate t to the disc.

The post, plate positioning sections and inner ring segment support the plate segments. Other raised structures on the back face are not needed to support the plate segments.

A light weight refiner or disperser plate segment has been invented comprising radially inner and outer edges; a front face with refining or dispersing features, a back face including a post ing a bolt hole and a raised plate positioning section, wherein the post and plate positioning n e surfaces configured to abut against a disc mounting e.

One embodiment of this light weight plate segment removes material from the backside of the segment, such as all side and outer diameter (OD) support material, ribs, or support material being strips or mass of solid metal material, and removes most, but not all, reinforcement ribs or support material other than those supporting the plate positioning sections. The embodiment allows reduction in overall weight of the plate segment. The light weight plate segment is less costly to manufacture, easier and less costly to transport, easier to handle (less manpower required to move and install the plates), quicker to install, and safer to handle in both manufacturing and customer es. This light weight segment allows customers to further optimize their ing and maintenance processes by providing flexibility in the replacement frequency of the plate segments as the plate segments are quicker, safer and easier to change, thereby reducing the costs ated with their replacement.

In an embodiment of the ion the borders or edges of the plate segment are removed with the ion of the border or edge facing the feed flow (such as the inner periphery or diameter). That is, three of the four plate segment borders or edges are removed. The removal of these plate segment borders or edges (three of the four borders or edges) results in even further reduction of the weight of the plate segment.

A border at the inner periphery or diameter of the plate segments, remains such that a ring (referred to as an inner ring or face ring) is formed at the inner diameter of the plates segments. The inner periphery border is important to support the seal. This inner ring may be formed in one piece and assist in positioning the plate t on the disc. The inner ring may be a , solid ring section at the radially inward edge of the plate segment. The inner ring allows for improved congruent placement of the plate segments to the disc mounting surface, thereby forming a smooth, continuous series of plate segments into a complete plate.

A seal may be in a grooved space, e.g., about 0.5 to 2.5 mm, between the inner ring and the disc. The seal may be formed by a suitable material, such as a soft flexible seal material or a hard metal to metal seal material.

The light weight plate segments tend to be easier and safer to , less costly to manufacture, and apply lower forces to the disc. ement of the conventional plate segments with the light weight plate segments may be accomplished quickly. Due to their lighter weight, there is less risk of physical injury to the mill personnel and to personnel involved in the manufacturing of the light weight plate segments. Light weight plate segments can be moved and mounted to the discs quickly as compared to conventional heavier plate segments.

Because the light weight plate segments may be quickly and easily replaced, the period between plate replacements may be ned without substantially increasing the overall downtime of the r or disperser. As the plate segments may be more frequently replaced without decreasing the ing time for a e, the surface condition of the plate segments over a machine operating period is better (i.e., less worn) than the conventional solid back heavy plate segments. Thus, using the new light weight plate segments in refiners or dispersers allows for a better refining (e.g., fiber rubbing) or dispersing (e.g., contaminant breakage and further removal) action to be ined which results in an improved final product. shows the back face of a light weight plate segment 200 for a plate segment according to one embodiment of the invention ence numbers are similarly labeled for similar parts as in . It has been found a significant amount of the mass (i.e., ), can be removed from a conventional plate segment without losing ural integrity while providing a light weight plate segment 200.

The back face of the light weight plate segment 200 is a substantially flat surface 205, which has a thickness T1, T2 similar to the thickness of the narrowest thickness of a conventional plate segment. The flat surface 205 may be truly planar or may have a slight curvature along a radial direction.

The thickness T1, T2 of the light weight plate segment 200 may be substantially constant over the flat e 205, or the thickness T1, T2 may gradually narrow in a radially outward direction. For example, T1 may be wider than T2 by a factor of 1.2 to 2.5. The thickness T1, T2 may be measured from the flat surface 205 of the back face to the front face and particularly to the bottom of the s between the bars on the front face or to the mounting surface at the bottom of the teeth on the front face. The thickness T1, T2 may be in a range of 1.0 to 1.5 inches (25 to 38 millimeters (mm)).

The back face of the light weight plate segment 200 lacks the extensive conventional network of ribs 110 and other raised surfaces, such as shown in In particular, the segment 200 lacks raised edge ribs 140. The interior ribs 270 are limited to ribs extending from the posts 260 surrounding the bolt holes 220. The surfaces on the back face that abut the mounting surface of the disc mounting surface (see may be limited to the upper surfaces of the posts 260 and the upper and side surfaces of plate positioning sections that are radially outward of the posts 260. Other es of the back face, such as the ntially flat surface 205, may not touch the surface of the disc that s the back surface. An inner ring-section may be included along a radially inward edge of the t (see FIGS. 3 to 12). The inner ection may also abut the e of the disc ng surface 205.

The plate positioning sections 210 and the posts 260 surrounding each of the bolt holes 220 may be the primary raised sections on the back face of the light weight plate segment 200. The plate oning sections 210 and posts 260 may also include the contact surfaces 212, 215 that abut the disc mounting surface and support the plate segment when mounted to the disc mounting surface. If the disc mounting surface has a flat contact surface, then the contact surfaces 212 on the posts 260 and the contact surfaces 215 on the plate positioning sections 210 may be substantially flat and in a common plane. Alternatively, if the disc mounting surface is conical, the contact surfaces 212, 215 may conform to a conical surface. The contact surfaces 212, 215 cooperate with bolt fasteners to align the light weight plate segments 200 with respect to the disc ng surface, and the bolt fasteners and contact surfaces 212, 215 carry the forces applied to the light weight plate segments 200.

The plate positioning sections 210 may also have an outer sidewall with a contact surface 280 that abuts a rim or post 260 on the disc mounting surface. T he sidewall contact surfaces 280 align the radial position of the plate segment on the disc mounting e and carry radial forces applied to the plate segment 200. The sidewall contact surfaces 280 replace the “butt pads” on conventional plate segments.

The plate positioning sections 210 may be at the radially outer edge of the plate segment 200 or on the back face between the outer edge and the post 260. Each plate positioning section 210 may be radially aligned with a post 260 such that a radial line from an axis of the disc to which the plate segment 200 is mounted passes h both the post 260 and the plate positioning section 210. Ribs, such as parallel ribs 270 extend from the post 260 to the plate oning sections 210. The ribs 270 may have a height less than the height of the post 260 or plate positioning sections 210. The ribs 270 may also be a pair of ribs 270 ing from the post 260 to the plate positioning section 210. The ribs 270 provide structural support for the plate positioning sections 210 and posts 260. The ribs 270 may extend along radial lines from an axis of the disc or be parallel pairs of ribs 270.

In some embodiments, the ribs 270 may have the same height as the outer periphery plate positioning sections 210 (solid material sections) and may end at the post 260 where the height at the plate positioning n 210 end is in a range of between the post 260 height and half the height of post 260.

The width W of the contact surface 215 on the plate positioning sections 210 may be substantially, e.g., within 20 t, of the diameter of the post 260. For example, the width W of the contact surface 215 and diameter of the post 260 may be in a range of 3 mm to 30 mm. The height of the plate positioning section 210 and post 260 may also be substantially, e.g., within 20 percent, the same or in a range of 2 mm to 50 mm. shows the back face of a second embodiment of the light weight plate segment 300 (reference numbers are similar for similar parts as .

An inner ring 330 abuts a ly inward edge of the light weight plate segment 300. The inner ring 330 may be an annular ring fixed to the disc ng surface to form an abutting surface to the inner edges of the light weight plate segments 300. In another embodiment, the inner ring 330 may be separate from the disc mounting surface. The inner ring 330 forms a dam or seal between the disc mounting e and light weight plate segment 300 to prevent loose feed material and debris from entering a region between the back face of the light weight plate segment 300 and disc mounting surface.

The inner ring 330 may be a separate component from the light weight plate segment 300 to avoid adding mass to the plate segment. The inner ring 330 may be a one piece annular ring that fits around the center cap (not shown) of the refiner or disperser. The inner ring 330 may have a width WE of approximately 1 inch (25 mm) and a height substantially the same as the thickness of the light weight plate segment 300 at the inner most edge 385 of the light weight plate t 300. A seal 390 may be placed between the inner most edge 385 of the light weight plate segment 300 and the outermost edge 350 of the inner ring 330. The seal 390 is made of suitable material (material capable of withstanding the operating environment of temperature, chemicals, etc. in a r or disperser) During manufacturing, e.g., casting, of the light weight plate segments 300, tighter tolerances on the sides of the light weight plate segments 300 may be to reduce the opening between adjacent light weight plate segments 300 when mounted to the stator or the rotor disc, thereby removing the need for a raised border (such as edge rib 140 shown in FIGURE 1) along the side edges. The light weight plate segments 300 may either be cast or machined to achieve tighter nces. When using the inner ring 330 along with the tighter cturing tolerances, little or no material will flow behind the light weight plate segment 300 by way of the opening in between the light weight plate segments 300 when placed y-side to form a complete plate.

The inner ring 330 prevents feed material entering the region between the plate segments and mounting surface of the disc. Feed al going between the plate segment and the mounting surface of the disc cause plate segment balance problems. If the light weight plate segments 300 become off balance, the refiner or disperser machine may begin to vibrate and would need to be shut down for cleaning and replacement of the light weight plate segments 300 (the same being true for tional plate segments 100 as shown in .

The inner ring 330 may be the thickness of the thickest part of the light weight plate segment 300, and may be removed from the surface of the disc or may remain in position on the disc allowing for easy removal of the light weight plate segment 300. The inner ring 330 may also be part of the center cap of the r or disperser. The inner ring 330 as a onal feature may also be integrated into the center cap, so that it is not a separate part.

This inner ring 330 need not come in direct contact with the light weight plate segments 300. Its primary purpose is to prevent the fiber material from getting to the back side of the light weight plate segments 300. The light weight plate segments 300 can be either cast or machined to achieve tight enough nces in between them, so that the fiber does not go behind the light weight plate segments 300. Outer diameter edge of the light weight plate ts 300 is left open with the idea that centrifugal force will keep the area free of unwanted material. The material of the inner ring 330 is a material suitable for use in the abrasive nment experienced by plate segments of the r and disperser machines. is a cross-sectional view of the side of the light weight plate segment 400 and the inner ring 430. The front face has teeth 402 as would be on a disperser plate. The teeth 402 are also representative of the bars on a refining plate. The reduced mass of the light weight plate segment 400 is evident from the minimal raised structures on the back face 404. The structures include the post 260 nding the bolt hole 220 and the plate positioning section 210. The ribs 270 may be tapered to reduce their mass while providing structural support for the plate positioning section 210. The back face 404 may only abut a mounting surface of a disc via contact surfaces 215 and 210. Other surfaces on th e back face 404 may not touch the mounting surface of the disc.

The t surface 215 on the positioning section 210 and t surface 212 on the post 260 are in substantially the same contact plane 406.

The radially inner most edge 485 of the light weight plate segment 400 may also have a contact edge in the contact plane 406. Similarly, the inner ring 430 has a t surface in the contact plane 406. The contact plane 406 conforms to the mounting surface of the disc. If the mounting surface is not planar, e.g., conical, then the contact surfaces 215 and 212, as well as the inner most edge 485 and inner ring 430 are aligned with the mounting surface and not aligned in a plane.

The light weight plate segment 400 has an inner most edge 485 facing and opposite to the outermost edge 450 of the inner ring 430. The opposing edges may have es designed for one or more of simplicity, supporting a seal between the opposing edges and aligning the plate segment on the disc mounting surface. shows in cross-section an alternative for the radial inner edge region (A-A) of the light weight plate segment 400 (shown in and the inner ring 430. The opposing edge surfaces 481, 451 of the light weight plate segment 400 and inner ring 430 are straight (linear) in a direction of the axis of the refiner or disperser and arc-shaped in a direction perpendicular to the axis. The opposing edge surfaces 481, 451 have a simple shape. The space 495 between the opposing edge surfaces 481, 451 may be sufficiently narrow such that feed material cannot pass through the space 495 or iently wide to allow a seal to fit in the space 495. For example, the space 495 may be in a range of 0.5 to 2.5 mm, which is sufficiently narrow to prevent feed al entering the region between the back face of the light weight plate segment 400 and the disc mounting surface. The space 495 may be entirely breached by metal to metal contact between the light weight plate segment 400 and inner ring 430 at numerous points in the space 495. shows in cross-section an alternative light weight plate t 400A (for the radial inner region (A-A) shown in and the inner ring 430. In plate t 400A a grooved space 496 is formed on the opposing edge surfaces 482, 452, of the light weight plate segment 400A and inner ring 430. The grooved space 496 is between raised s on each edge surfaces 482, 452. The grooved space 496 formed between the opposing edge surfaces 482, 452 es a flexible seal 494 (such as a flexible o-ring or gasket or other suitable insert). The seal 494 fills the grooved space 496 and prevents feed al entering the region between the back face of the light weight plate segment 400 and the disc mounting surface. shows in cross section an additional alternative light weight plate segment 400B (for the radial inner region (A-A) of the plate in and the inner ring 430. The inner edge surface 483 of the light weight plate segment 400B is slanted, e.g., oblique, with respect to the axis of a refiner disc. The slanted inner edge surface 483 faces a slanted edge surface 453 on the inner ring 430. The slanted space 497 between the parallel inner edge surface 483 and the slanted edge surface 453 is also slanted. The d space 497 may have a space of between 0.5 to 2.5 mm, or sufficiently narrow, when used with the straight lower surface 454 of the ost edge of the inner ring 430 to prevent material entering from the refining/dispersing e of the refiner plate segments and becoming lodged in the region between the backside of the light weight plate segment 400B and the disc mounting surface.

The inner ring 430 may also include a lower surface 454 that is not slanted, e.g., parallel to the axis of the disc. The corner between the lower surface 454 and the slanted edge surface 453 provides an abutment to the slanted inner edge surface 483 of the light weight plate segment 400B. The abutment assists in preventing debris and feed material from passing through the slanted space 497.

In the inner ring 430 has a height H1 greater than the thickness T3 of the light weight plate t 400B. The lower surface 454 of the inner ring 430 extends through a region 493 between the back face of the plate segment and the disc mounting surface 492. shows in cross section yet another possible alternative light weight plate t 400C (for the radial inner edge region (A-A) in and the inner ring 430, wherein an inner lip 498 on the inner ring 430 may support the inner edge region of the light weight plate segment 400C. The light weight plate segment 400C includes a slanted inner ring edge surface 483 and faces a slanted edge surface 453 of the inner ring 430. The height H2 of the inner ring 430 is r than the thickness T4 of the light weight plate segment 400C.

The inner lip 498 extends radially outward under an inner portion of the light weight plate segment 400C. The inner lip 498 and the corner between the inner lip 498 and d space 497 prevent feed material and debris from entering the region 493 between the light weight plate segment 400C and disc mounting surface 492. A seal (not shown) may be positioned in the region 493 and between the inner lip 498 and the light weight plate segment 400C. is a cross-sectional view of a light weight plate segment 500 and is an enlarged cross-sectional view of section B shown in The inner most edge 585 of the light weight plate segment 500 is configured to be adjacent the disc mounting surface 586 of the annular disc 587. The contact surfaces 212 on the post 260 and contact surface 215 on the plate positioning section 210 abut the disc mounting surface 586. A back face ring n 588 faces the mounting surface 586. A groove d sector 510 in the back face ring section 588 receives a seal 520, e.g., a deformable annular seal, which may be fixed to the disc mounting surface 586 or be separate from both the light weight plate segment 500 and the disc mounting surface 586. The seal 520 may have a cross sectional shape that is ar, oval, rectangular, triangular, octagonal, or combinations there of, or any suitable shape that may be suitable to be ed by grooved sector 510.

The grooved sector 510 may be located near and radially outward of the inner most edge 585 of the light weight plate segment 500. The seal 520 n the back face ring section 588 and disc mounting surface 586 prevents feed material and debris entering the region n the light weight plate segment 500 and disc mounting surface 586. shows another light weight plate segment 400 having a back face 404 which is largely devoid of raised structures. The post 460 for the bolt holes 420, the plate positioning sections 410 and ribs 470 are similar to raised structures shown in FIGS. 2, 3 and 9. The raised structures may also include a finger 411 and bar 412 which provide for grasping by devices for moving the light weight plate segment 400 while not attached to a disc mounting surface (especially during the manufacturing s). Even with the finger 411, bar 412, post 460 and plate positioning sections 410, the back face 404 remains largely unencumbered by raised es and the mass associated with extensive raised surfaces. In some embodiments, finger 411 and bar 412 may not be present.

The inner most edge 414 is similar to the inner most edge 585 shown in . The inner most edge 414 has a back face 404 configured to oppose the disc mounting surface. A grooved sector 416 is similar to the grooved sector 510 in , and is configured to seat over a seal (not shown) on a mounting surface. is a side view of a pair of light weight plate segments 710, 712 each mounted on a mounting surface of a disc 714, 716. The light weight plate segments 710, 712 are arranged side-by-side to form an r array on the mounting surface of the disc 714, 716. The plate segments 710, 712 are mounted onto the mounting surface of the disc 714, and not mounted onto adjacent plate segments in the annular array. The disc 714, 716 may be a rotor and a stator disc of a ser (as shown in Figure 12) and the light weight plate ts 710, 712 may have teeth for dispersing ink and other contaminants from recycled paper and other materials. The plate segments may alternatively have bars and grooves and be mounted to discs for a refiner (not shown).

A fastener, such as a bolt 718, extends from the disc 714, 716 into the bolt holes of the posts 720 on the back face of the light weight plate segments 710, 712. The bolts 718 fasten the light weight plate segment 710, 712 to the disc 714, 716. The contact surface 722 on the post 720 and the contact surface 724 on the plate oning sections 726 abut the disc mounting e 728 of the disc 714, 716. The bolt fastener and the nts between the t surfaces 722 and the mounting surface 728 fix the light weight plate segment 710, 712 to the disc 714, 716.

A ledge 730 on disc mounting e 728 may abut a sidewall contact surface 732 on each of the plate positioning sections 726. Th e ledge 730 resists radial movement of the light weight plate segment 710, 712 and aligns the light weight plate segment 710, 712 on the disc 714, 716. An annular seal 734 on the disc mounting surface seats in a space 736 on an inner edge region of the light weight plate segment 710, 712. The seal 734 prevents feed material (represented by arrow 738) from getting in the region behind the light weight plate segment 710, 712 and between the light weight plate segment 710, 712 and disc 714, 716. The feed mater ial 738 moves radially outward and between the opposing front faces of the light weight plate segment 710, 712. is a flow chart showing an exemplary casting process to manufacture the plate segment. Steps shown in the flow chart that are connected by solid lines refer to red steps of the process. Steps connected by dotted lines indicate optional steps of the process.

The plate segments may be formed by casting metal. Conventional manufacturing processes include pouring melted metal into a mold having the desired design for the specific plate segment of interest. Once the molded plate segment has cooled, the plate segment is removed from the mold and sent for cleaning and gate removal followed by grinding and rough inspection including bolt hole preparation, a second grinding step, robotic grinding of the plate segment prior to heat treatment and precision grinding.

For the light weight plate segments disclosed , a modified conventional manufacturing process is possible. The modified cturing process provides a lighter weight plate segment, thereby significantly reducing manufacturing steps and cost of cturing without adversely impacting the th of the new, r weight plate segment.

Manufacturing of the light weight plate segment design begins with casting of the plate segment by taking molten metal 901, and g molten metal into a mold 910. The mold to be used has the new back face surface design that is largely devoid of raised surfaces, such as the conventional network of ribs and particularly the ribs around the edges and sides of the segment. The mold may include features for forming the raised surfaces, such as the post, positioning section and mass support ribs. Once the mold has been filed with molten metal, the molded plate segment is allowed to cool 912 to a temperature that is sufficient for safe handling.

The cooled light weight plate segment is removed from the mold. The molded plate is cleaned and g gates are removed 914 by ng.

Rough inspection and bolt hole preparation are also performed on the molded light weight plate segment. At this point the light weight plate segment may be ready for shipment 918 to the customer 950, or optionally, the light weight plate segment may o the manufacturing steps of robotic rough grinding 920 and possibly precision grinding 922, and heat treatment 924 before shipment 918. If the optional manufacturing process step of heat treatment is excluded, the metal material used to form the light weight plate segment may have sufficient strength to produce a light weight plate segment such that a heat treatment step is unnecessary.

Due to the lower manufacturing costs of the light weight plate segment, a mill plan with rs or dispersers may be able to afford more frequent replacement of sets of plate segments. Replacement of the light weight plates can be lished more easily, in less time and safer as compared to heavier plates. More frequent replacement of plates allows for more efficient refining or sing because the plates are replaced before their bars or teeth become dull or broken.

When an inner ring is present, the light weight plate segments may be removed from the stator and rotor discs without removing the inner ring itself.

The inner ring may be incorporated to the center cap of the disc. When the inner ring becomes damaged or requires replacement it is removed at the same time as the light weight .

Using the combined light weight plate segment and the inner ring in the inner diameter of the light weight plate segment will result in multiple advantages over the conventional plate segments used in refining and dispersing machines. These advantages include: less material needed to cture the plate segments; ease of removing and installing the plate segments thereby reducing time required to remove and install plate segments; reduced transportation costs for both the new plate segments being delivered to the mill and the cost to return used plate segments (used plate segments are typically returned to the manufacturer so the metal can be reclaimed); because of the lighter weight of the plate segments, handling of the light weight plate segments is safer for the mill personnel as well as others involved in the transport of the plate ts.

In another alternative embodiment, the backside of the light weight plate t may have a groove space on the backside of the plate t to hold a seal. The groove space for the seal is set back, radially inward from the edge of the inner periphery of the backside of the light weight plate segment. The seal al is a flexible material capable of withstanding the ing (temperature, chemical, etc.) environment of the machine without decomposing while holding the light weight plate segment to the mounting surface of the disc.

Throughout this ication, the term “comprising” and its grammatical equivalents should be given an inclusive meaning unless the context of use indicates otherwise.

The applicant does not concede that the prior art discussed in this specification forms part of the common general knowledge.

While preferred embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. ingly, it is to be understood that the present invention has been bed by way of illustration and not limitation.

Claims (26)

We claim:

1. A plate segment configured to be d on a disc of a disperser or refiner of comminuted cellulosic material, the segment comprises: a front face of a plate segment including disperser teeth or refining bars; a back face of a plate segment on an opposing major e to the front face, ing a raised post surrounding a fastener attachment structure and a raised plate positioning section; side edges of the plate segment located along edges of the front face and the back face; and a radially outer edge and a radially inner edge extending between the side edges; wherein the back face lacks raised structures along the side edges.

2. The plate segment in claim 1, wherein the raised post is aligned along an imaginary radial line extending from a rotational axis of the disperser or refiner.

3. The plate segment in accordance with any one of claim 1 or claim 2 r comprising a second post and a second plate positioning section aligned along an imaginary radial line ing from a rotational axis of the disperser or refiner.

4. The plate segment in accordance with any one of the preceding claims, wherein the radially outer edge is devoid of a raised structure.

5. The plate segment in accordance with any one of the preceding claims, wherein the raised post and raised plate positioning section each have t es, and the contact surfaces are aligned in a common plane.

6. The plate segment in accordance with any one of the preceding claims further comprising a rib extending radially outward from the post to the plate positioning section.

7. An assembly of a disc and a plate segment for a refiner or disperser comprising: a plate segment including a front face having disperser teeth or refining bars, a back face having a raised post surrounding a fastener attachment structure and a raised plate positioning section; side edges located along edges of the front face and back face, and a radially outer edge and a radially inner edge ing n the side edges, wherein the back face lacks raised structures along the side edges; and a disc having a disc ng surface configured to mount the plate segment, the disc ng surface abuts the post and plate positioning section of the plate t.

8. The assembly in accordance with claim 7 further comprising plate segments mounted side by side on the disc mounting surface to form an annular array on the mounting surface of the disc, and the plate segments are not mounted to adjacent plate segments.

9. The assembly in accordance with any one of claim 7 or claim 8 further comprising a spaced region between the plate segment back surface and the disc mounting surface in which the back surface do not abut the disc mounting surface except for a surface on the raised post and the raised plate positioning n that abut the disc mounting surface.

10. The assembly in accordance with any one of claims 7 to 9 further comprising an annular ring on the disc mounting surface, n the annular ring is radially inward and adjacent to the radially inner edge of the plate segment.

11. The assembly in accordance with claim 10, wherein a surface of the radially inner edge of the plate segment faces a surface of the annular ring, and the surfaces are ht in a direction of a rotational axis of the refiner or disperser.

12. The assembly of claim 11, wherein an annular space between the facing surfaces has a thickness in a range of 0.5 to 2.5 mm.

13. The ly of any one of claims 11 or 12 wherein a surface of the radially inner edge of the plate t faces a surface of the annular ring, and the surfaces form an annular partial space to receive an annular seal.

14. The assembly of any one of claims 11 to 13, wherein the surfaces abut at various points along the inner edge of the plate segment.

15. The assembly of claim 10, wherein a e of the radially inner edge of the plate segment faces a surface of the annular ring, the surfaces each have a grooved space, and the grooved spaces form a track to receive an annular seal.

16. The assembly of claim 15, wherein the annular seal is a deformable seal.

17. The assembly in accordance with claim 10,wherein a surface of the radially inner edge of the plate segment faces a surface of the r ring, and the surfaces are parallel to each other and oblique to a direction of a rotational axis of the refiner or a disperser.

18. The assembly of claim 17, n the e of the annular ring includes a lip extending underneath the plate segment.

19. The assembly of claim 17 or 18, wherein the annular ring has a thickness greater than the thickness of the plate segment at the ly inward edge, such that the radially inward edge does not abut the disc mounting surface.

20. The assembly of claim 15, wherein the annular seal is in a shape of circular, oval, rectangular, triangular, octagonal, or ations thereof.

21. A plate segment comprising: a front face on a plate segment, including disperser teeth or refining bars; a back face on a major surface of the plate segment opposing the front face, ing a raised post surrounding a fastener attachment structure and a raised plate positioning n; side edges of the plate segment located along edges of the front face and the back face; a radially outer edge and a radially inner edge extending between the side edges; and a grooved space on the back face and adjacent to the radially inner edge, the grooved space is configured to receive a seal; wherein the back face lacks raised ures along the side edges,.

22. The plate segment of claim 21, wherein the ly inner edge of the back face is in a common plane with contact surfaces on the post and plate positioning section.

23. A method to form a plate segment comprising: casting a plate segment by pouring molten metal into a mold, wherein the mold includes impressions for a back face of the plate segment that lacks raised ribs along sidewalls of the back face; cooling the plate segment and removing the segment from the mold after pouring the molten metal; cleaning and ng casting gates from the cooled plate segment; grinding the cooled plate segment.

24. The method of claim 23, wherein the grinding of the plate segment includes an automated robotic rough grinding step ed by a manual precision grinding step.

25. The method of any one of claims 23 or 24, wherein the plate segment is configured for use in a refiner or a disperser.

26. The method of any one of claims 23 to 25, wherein the impressions in the mold for the back face are d to impressions for at least one fastener support post, at least one plate positioning section radially aligned with each fastener support post, and at least one rib extending between each aligned fastener support post and plate positioning section.