阅读说明：本技术 泄水槽以防止相对精磨机板的空蚀 (Drainage grooves to prevent cavitation of opposed refiner plates ) 是由 马克·伯格 卢克·金格拉斯 于 2018-12-14 设计创作，主要内容包括：本公开涉及精磨机板节段、机械精磨机和制造精磨机板节段的方法,所述精磨机板节段具有一个或多个水通道,所述水通道沿着精磨机板节段基部的径向长度设置在可变的基底轮廓中并设置在精磨机板节段入口和主要精磨部之间,其中,所述可变的基底轮廓包括起伏曲线,该起伏曲线配置成与相对的精磨机板上的第二起伏曲线互补,而且所述一个或多个水通道的大小足够窄以防止木屑进入水通道并且足够宽以为自由水提供旁路路径。(The present disclosure relates to refiner plate segments, mechanical refiners and methods of manufacturing refiner plate segments having one or more water channels disposed in a variable base profile along the radial length of the refiner plate segment base and between the refiner plate segment inlet and the primary refiner portion, wherein the variable base profile includes a relief curve configured to complement a second relief curve on the opposite refiner plate, and the one or more water channels are sufficiently narrow in size to prevent wood chips from entering the water channels and sufficiently wide to provide a bypass path for free water.)

1. A refiner plate segment for a mechanical refiner comprising:

a substrate having:

a radial length;

a narrow side disposed at a first end of the radial length;

a wide side disposed at a second end of the radial length, the wide side positioned radially away from the narrow side along the radial length, the wide side being wider than the narrow side;

a first side extending along a radial length between the narrow side and the wide side;

a second side extending along a radial length between the narrow side and the wide side, the second side disposed distally from the first side; and

a rear face disposed opposite the front face along the thickness, the rear face and the front face extending between the wide side, the narrow side, the first side and the second side,

wherein the front face further comprises a region having a plurality of alternating breaker ribs and wide grooves, wherein the breaker ribs engage the base and adjacent breaker ribs and base define the wide grooves between adjacent breaker ribs,

wherein the substrate further comprises a variable substrate profile disposed between the broad side and the narrow side, the variable substrate profile comprising:

a trough at a first radial position on the front face,

an adjacent crest at a second radial position on the leading face, wherein the leading face connects the trough and the adjacent crest, an

Wherein the substrate further comprises a water channel, a first end of the water channel being arranged closer to the narrow side than a second end.

2. The refiner plate segment of claim 1 wherein the water channel further comprises a comparative channel depth, wherein the height between the trough and adjacent crest of the variable base profile is a "full-convex profile height" and the comparative channel depth is between one-half of the full-convex profile height and the full-convex profile height.

3. The refiner plate segment of claim 1 wherein the first end of the water channel has a first end width of between 2 mm and 5 mm.

4. The refiner plate segment of claim 1 wherein the number of the plurality of water channels is at least the same as the number of the transverse breaker bars.

5. The refiner plate segment of claim 1 wherein a first end of the water channel has a first width and a second end of the water channel has a second width, wherein the second width is greater than the first width.

6. The refiner plate segment of claim 1 wherein a base sidewall extends linearly between the first and second ends.

7. The refiner plate segment of claim 6 wherein the first end width is at least 2 mm and the second end width is about 5 mm.

8. The refiner plate segment of claim 1 wherein the first end of the water channel has a first height and the second end of the water channel has a second height, and wherein the second height is greater than the first height.

9. The refiner plate segment of claim 1 wherein the water channel is disposed in the base.

10. The refiner plate segment of claim 9 further comprising a plurality of water channels disposed in the base.

11. The refiner plate segment of claim 9 wherein the first end of the water channel has a shape selected from the group consisting of circular, elliptical, polygonal, quadrilateral, and rounded rectangular.

12. The refiner plate segment of claim 9 wherein two or more of said plurality of water channels merge along the radial length of the refiner plate segment such that the merged water channel has more first ends than second ends.

13. The refiner plate segment of claim 1 wherein the water channel further comprises a water channel trough at a first radial position on the channel bottom and an adjacent water channel crest at a second radial position on the channel bottom, wherein the channel bottom connects the water channel trough and the adjacent water channel crest in a straight line, a concave curve, a convex curve, or an S-shaped curve.

14. The refiner plate segment of claim 13 wherein the water channel further includes a comparative peak depth defined by the difference between the adjacent water channel peak and the adjacent variable base profile peak, wherein the height between the trough and the adjacent peak of the variable base is a "fully convex profile height" and the comparative channel depth is less than or equal to the fully convex profile height.

15. The refiner plate segment of claim 1 wherein the variable base profile forms a transverse wave shape.

16. The refiner plate segment of claim 1 wherein the water channel bottom is formed in the shape of a transverse wave.

17. The refiner plate segment of claim 1 wherein the water channel further comprises a plurality of water channel troughs alternating between a plurality of water channel peaks, each water channel peak being adjacent to at least one water channel trough.

18. The refiner plate segment of claim 1 wherein the variable base profile further includes a plurality of troughs alternating between a plurality of crests, each crest being adjacent to at least one trough.

19. The refiner plate segment of claim 1 wherein the base defines a water channel having a channel bottom and a distally disposed base sidewall extending between a water channel first end and a water channel second end, the channel bottom being disposed within the base below the front face.

20. A mechanical refiner comprising:

a first refining assembly having a center of rotation on an axis and configured to rotate about the axis; and

a second refining assembly facing the first refining assembly, wherein the first and second refining assemblies each comprise:

a backing structure and a plurality of refiner plate segments annularly arranged and fixedly joined to the backing structure, the refiner plate segments having:

a substrate, comprising:

the length of the radial direction is longer than that of the radial direction,

disposed on the narrow side of the first end of the radial length,

a wide side disposed at a second end of the radial length, the wide side positioned radially away from the narrow side along the radial length, the wide side being wider than the narrow side,

a first side extending along a radial length between the narrow side and the wide side,

a second side extending along a radial length between the narrow side and the wide side, the second side disposed distally from the first side,

a back surface disposed opposite the front surface, the back surface and the front surface extending between the broad side, the narrow side, the first side, and the second side, the back surface disposed on the backing structure,

wherein the front surface further comprises a zone having a plurality of alternating refining bars and grooves, wherein the refining bars engage the base, and wherein adjacent refining bars and base define grooves between adjacent refining bars, wherein the zone of alternating refining bars and grooves is referred to as a "refining section",

wherein the base further comprises a variable base profile disposed between the refining section and the narrow side, the variable base profile comprising:

a trough at a first radial position on the front surface,

an adjacent crest at a second radial position on the front surface, wherein the front surface connects the trough and the adjacent crest, an

Wherein the substrate further comprises a water channel, a first end of the water channel being arranged closer to the narrow side than a second end.

21. The mechanical refiner of claim 20 wherein said second refining assembly has a center of rotation on said axis and is configured to rotate about said axis.

22. The mechanical refiner of claim 20 wherein said mechanical refiner is selected from the group consisting of a rotor-stator refiner, a counter-rotating refiner, a double disc refiner, a disc-cone refiner and a cone refiner.

23. The refiner plate segment of claim 20 wherein the base defines a water channel having a channel bottom and a distally disposed base sidewall extending between a water channel first end and a water channel second end, the channel bottom being disposed within the base below the front face.

24. A refiner plate segment for a mechanical refiner comprising:

a substrate having:

a radial length;

a narrow side disposed at a first end of the radial length;

a wide side disposed at a second end of the radial length, the wide side positioned radially away from the narrow side along the radial length, the wide side being wider than the narrow side;

a first side extending along a radial length between the narrow side and the wide side;

a second side extending along a radial length between the narrow side and the wide side, the second side disposed distally from the first side; and

a back surface spaced a thickness from the front surface, the back surface and the front surface extending between the wide side, the narrow side, the first side, and the second side,

wherein the front surface further comprises a zone having a plurality of alternating refining bars and grooves, wherein the refining bars engage the base, and wherein adjacent refining bars and base define grooves between adjacent refining bars, wherein the zone of alternating refining bars and grooves is referred to as a "refining section",

wherein the base further comprises a variable base profile disposed between the refining section and the narrow side, the variable base profile comprising:

a trough at a first radial position on the front surface,

an adjacent crest at a second radial position on the front surface, wherein the front surface connects the trough and the adjacent crest in an S-shaped curve, an

Wherein the substrate further comprises a water channel having a first end disposed closer to the narrow side than a second end disposed closer to the wide side, the substrate defining a water channel having a channel bottom disposed within the substrate below the front surface and a distally disposed substrate sidewall extending between the water channel first end and the water channel second end.

25. The refiner plate segment of claim 24 further comprising a crusher bar disposed between the narrow side and the refining section, wherein the base further comprises a plurality of water channels.

26. A refiner plate segment according to claim 24 wherein the water channel is provided in the base between the narrow side and the refining section.

27. A method of manufacturing a refiner plate segment having water channels disposed between a narrow side of a refiner plate and a refining section and having a variable base profile, the method comprising:

water channels are created in the variable substrate profile using additive manufacturing techniques, the first ends of the water channels being disposed closer to the narrow side than the second ends, the water channels being disposed in the substrate below the front surface.

28. The method of claim 27, further comprising creating water channels within the substrate using additive manufacturing techniques.

29. The method of claim 27, wherein the additive manufacturing technique is selected from the group consisting of selective laser sintering, selective laser melting, electron beam melting, binder jetting, and material jetting.

Technical Field

The present disclosure relates generally to refiners for lignocellulosic materials and more particularly to refiner plate segments for refiners.

Background

Mechanical pulp refiners typically separate, develop and cut lignocellulosic material into fibers to impart certain mechanical and physical properties to the fibers, suitable for use in pulp, paper, paperboard, building materials, packaging materials, liquid absorbent filling materials, and other products.

Mechanical refiners typically comprise two or more opposing refiner elements. Each assembly has a raised refining edge pattern on the refining side. The grooves separate adjacent refining bars. Typically, these refining assemblies are circular discs, annular discs or nested cones configured to rotate about a common axis. Each refiner assembly may comprise a plurality of annular sector segments bolted to a backing structure to form a refiner disc, a refiner ring disc or a refiner cone. The refining sides of the opposing refiner assemblies face each other to define a narrow refining gap separating the opposing refiner assemblies. At least one of the refining assemblies is a rotor configured to rotate about an axis.

When the rotor refining assembly rotates at high speed, the operator feeds lignocellulosic material or other feed through the refining gap. As the rotor rotates, the refining bars and grooves on opposing refiner elements overlap one another. Typical rotor refiner assemblies rotate in the range of 900 to 2, 300 revolutions per minute ("rpm"). The successively overlapping opposite ribs and grooves alternately compress the lignocellulosic material and allow it to expand in the refining gap. This rapid alternating compression and expansion creates a fibrous mat, which is the primary location where mechanical refining occurs. In other words, the strong movement of the feedstock relative to the adjacent feedstock in the fiber mat primarily contributes to the development, separation and cutting of the fibers. This is called "primary refining".

When a mechanical refiner breaks down lignocellulosic material, some water may be released in the form of steam. The steam is divided into a "forward flow" portion, which flows out of the refining gap together with the refined fibres, and a "return flow" portion, which will return towards the inlet of the refiner plate segment. Typically, the operator thermally softens the lignocellulosic material prior to the primary refining step, and the return steam is typically the primary heat source for thermally softening the lignocellulosic feed. However, the reflux steam thermally softens the feed material inconsistently, in part because of the inconsistency in the feed particle size.

The size of the feed material tends to be inconsistent and many conventional refiner plates do not sufficiently break down the feed material (e.g., lignocellulosic material) before feeding it into the refining gap for primary refining. As a result, mechanical refiners typically distribute energy unevenly to the differently sized feed material, which may result in uneven refining. That is, as larger particles enter the primary refiner section, the larger particles tend to suffer more fiber damage (usually in the form of cutting) than do the smaller particles.

Small amounts of refiner plates that can sufficiently break down the feed tend to lack feed strength control, lack feed distribution control, and/or suffer from increased negative interaction between the return steam and the feed.

To address these problems, applicants have developed refiner plate segments described in U.S. patent No. 6,616,078, "refiner plates with chip conditioning inlets," the entire contents of which are incorporated herein by reference ("the' 078 patent"). The' 078 patent describes a refiner plate having an undulating variable base profile extending along the radial length of the refiner plate segment base radially inward of the primary refining edge. The variable base profile on a first refiner plate segment directs feed material onto an opposing refiner plate segment at a first fixed radial position. The variable base profile of the opposing second refiner plate segment then directs the same feed material back to the first refiner plate segment at a second fixed radial position. The second fixed radial position is disposed radially outward from the first fixed radial position.

However, the design disclosed in the' 078 patent may also constantly deflect excess steam and dilution water to a fixed radial position. The design of the' 078 patent results in substantial cavitation where water strikes opposing segments. Cavitation damage tends to be most severe where water is first deflected to the opposing refiner plate segment. This problem results in a significant reduction in the service life of the refiner plate segment.

Disclosure of Invention

There is a need to develop a variant of the invention disclosed in the' 078 patent in which all features of chip transport are retained, but an alternative path is created for the free water entering the refiner feed to prevent cavitation of the refiner plate elements, thereby extending the effective plate life to an acceptable level.

The problem of cavitation erosion in refiner plate segments having a variable base profile along the radial length of the refiner plate segment base and disposed between the refiner plate segment inlet and the primary refiner portion is solved by adding one or more water channels disposed adjacent the high points of the undulation curve, wherein the variable base profile includes an undulation curve configured to complement a second undulation curve on the opposing refiner plate segment, the one or more water channels being sufficiently narrow in size to prevent wood chips from entering the water channels and sufficiently wide to provide a bypass path for free water as more fully described in accordance with the present disclosure. It is contemplated that the water channels as more fully described herein may eliminate most or substantially all of the free water that would otherwise impact the opposing refiner plate segment at a fixed radial position.

The depth of the water channel may be half the full height of the raised profile for deflecting wood chips to the counter element up to the full height of the raised profile for deflecting wood chips to the counter element. In other exemplary embodiments, the depth of the water channel may be deeper than the full height of the raised profile. Preferably, the channel will be in an area 2-5mm wide to prevent the chips from passing easily through the channel. Fine particles can pass through the channels, but these very fine particles do not require pre-treatment (e.g., grinding the feed to a more uniform average size prior to refining). Different embodiments may have different numbers of channels. In a preferred embodiment, the number of channels is such that the channels sufficiently redirect water that would otherwise be pushed through the gap and hit the opposite refiner plate element. The number may be at least as large as the number of feed edges (i.e. wide edges or "breaker edges") extending towards the inlet of the first rotor element. Ideally, the profile of the water channel should be such that the width of the water channel is seen to be slightly flared as one travels from the inlet side of the refiner plate towards the periphery to ensure as much as possible that any solid particles entering such a water channel mouth will not end up being trapped in the slot mouth.

In certain exemplary embodiments, the refiner plate segment may have at least one water channel. In other exemplary embodiments, the refiner plate segment may have two or more water channels.

The number of water channels, the size of the water channels and the position of the water channels in the crusher ridge section (or "feed section") may be configured to optimize the flow of free water to flow outwardly towards the refining section without being deflected to a fixed radial position on the opposite refiner plate segment. In this manner, the exemplary embodiments further described herein prevent severe cavitation at discrete radial locations on the refiner plate segments.

Drawings

The foregoing will be apparent from the following more particular description of exemplary embodiments of the disclosure, as illustrated in the accompanying drawings. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the disclosed embodiments.

Fig. 1A is a partially exploded perspective view of a mechanical disc refiner depicting how refiner plate segments are mounted to a backing structure.

Figure 1B is a perspective view of a fully assembled mechanical disc refiner showing the rotor and stator sides open.

Fig. 2A depicts an exemplary rotor refiner plate segment having exposed water channels in the crusher ridge portion.

Fig. 2B is a cross-sectional profile view of the refiner plate segment depicted in fig. 2A taken along line a-a.

Fig. 2C is a front view of an exemplary stator refiner plate segment.

Fig. 2D is a cross-sectional profile view of the refiner plate segment depicted in fig. 2C taken along line B-B.

Fig. 3A is a top view of a front surface of an exemplary refiner plate segment including a plurality of water channels disposed in the base of the refiner plate segment.

Fig. 3B is a side cross-sectional view of the exemplary refiner plate segment of fig. 3A taken along line C-C.

Fig. 4A is a cross-sectional side view of an exemplary refiner plate segment having a flat bottom water channel.

Fig. 4B is a cross-sectional side view of an exemplary refiner plate segment having a curved bottom water channel with a matching stator element.

Fig. 5 is a top view of a stacked exemplary refiner plate segment having a plurality of water channels disposed at an angle relative to the radial length of the refiner plate segment.

Fig. 6 is a cross-sectional view of an exemplary refiner plate segment having water channels disposed in a refiner plate substrate such that only the ends of the water channels are exposed to the refining environment.

Fig. 7A is a front view of a narrow side of an exemplary refiner plate segment including a plurality of water channels disposed in a refiner plate substrate.

Fig. 7B is a side cross-sectional view of the exemplary refiner plate segment of fig. 7A taken along line D-D.

Figure 7C is a front view of a broad side of an exemplary refiner plate segment including a plurality of water channels disposed in a refiner plate substrate. In the depicted exemplary embodiment, there are fewer second ends than first ends of the water channels.

Fig. 8 is a perspective view of an exemplary refiner plate segment having a plurality of water channels.

Detailed Description

The following detailed description of the preferred embodiments is presented for purposes of illustration and description only and is not intended to be exhaustive or to limit the scope and spirit of the invention. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications. Those of ordinary skill in the art will recognize that many changes may be made to the invention disclosed in this specification without departing from the scope and spirit of the invention.

Like reference numerals refer to corresponding parts throughout the several views unless otherwise specified. Although the drawings represent embodiments of various features and components in accordance with the present disclosure, the drawings are not necessarily to scale and certain features may be exaggerated to better illustrate embodiments of the present disclosure, and such exemplifications are not to be construed as limiting the scope of the present disclosure.

Unless otherwise explicitly stated herein, the following explanation rules apply to the present specification: (a) all terms used herein should be interpreted as having the required properties or number (singular or plural) as the case may be; (b) the singular terms "a", "an" and "the" when used in this specification and claims include the plural unless the context clearly dictates otherwise; (c) the antecedent "about" as applied to a recited range or value represents an approximation within the range or value of deviation known or accepted in the art for measurement; (d) the words "herein," "in accordance," "against," "above," and "below," and words of similar import, refer to this specification as a whole, not to any particular paragraphs, claims, or other subdivisions, unless otherwise specified; (e) descriptive headings are for convenience only and should not control or influence the meaning or structure of any part of the specification; and (f) or and "any" are not exclusive, and "including" are not limiting. Furthermore, the terms "comprising," "having," "including," and "containing" are to be construed as open-ended terms (i.e., meaning "including, but not limited to,").

References in the specification to "one embodiment," "an example embodiment," etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.

To the extent necessary to provide descriptive support, the subject matter and/or text of the appended claims is incorporated herein by reference in its entirety.

Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within any sub-range, unless otherwise indicated herein. Each separate value within the stated range is incorporated into the specification or claims as if each separate value was individually recited herein. Where a specific range of values is provided, it is understood that each intervening value, to the tenth or less of the unit of the lower limit between the upper and lower limit of that range, and any other stated or intervening value in that stated range or subrange thereof, is included unless the context clearly dictates otherwise. All subranges are also included. The upper and lower limits of these smaller ranges are also included, but are subject to any express and clear exclusion within the stated ranges.

It should be noted that many of the terms used herein are relative terms. For example, the terms "upper" and "lower" are positionally opposite to each other, i.e., the upper component is at a higher elevation than the lower component in a given direction, but these terms may vary if the device is flipped. The terms "inlet" and "outlet" are relative to a fluid that flows through them for a given structure, e.g., the fluid flows through the inlet into the structure and out the outlet of the structure. The terms "upstream" and "downstream" are relative to the direction of fluid flow through the various components, i.e., the flow of fluid through an upstream component before flowing through a downstream component.

The terms "horizontal" and "vertical" are used to indicate a direction relative to an absolute reference, i.e., a ground plane. However, these terms should not be construed as requiring structures to be absolutely parallel or absolutely perpendicular to each other. For example, the first and second vertical structures need not be parallel to each other. The terms "top" and "bottom" or "base" are used to refer to a position/surface where the top is always higher than the bottom/base relative to absolute reference, i.e., the earth's surface. The terms "upward" and "downward" are also relative to absolute reference; the upward flow is always opposite to the gravitational force of the earth.

Figure 1A depicts an example mechanical disc refiner 100 having a rotor refining assembly 101 disposed opposite a stator refining assembly 102. The rotor and stator assemblies 101, 102 are located within a housing 179. Each refining assembly 101, 102 includes a plurality of refiner plate segments 105, the refiner plate segments 105 being annularly arranged to form a ring mounted on the backing structure 174. Figure 1 shows the stator side 104 of the housing 179 open about a hinge 183 to better depict the respective refining assemblies 101, 102. However, during operation, the stator side 104 is closed about the hinge 183 and bolts (not depicted) extend through the respective bolt holes 182 to fixedly join the stator side 104 of the housing 179 to the rotor side 106. When the stator and rotor refining assemblies 102, 101 face each other, the stator and rotor refining assemblies 102, 101 define a gap 449 (fig. 4) between the front surfaces 119 of the opposing refiner plate segments 105, 105'. It will be appreciated that other mechanical refiners may have different access mechanisms (i.e. not necessarily the hinge 183).

For large diameter mechanical refiners 100, one or more rings of intermediate refiner plate segments may be disposed at the crusher bar segment 105_bWith the outer refiner plate segment 105_aIn the meantime. However, it will also be appreciated that such intermediate rings are rare. Bolts or fasteners may extend through the fastener holes 167 to engage the refiner plate segment 105 to the backing structure 174 to fixedly engage the annular segment refiner plate segment 105 to the backing structure 174.

As used herein, unless otherwise specified, "refiner plate segment" 105 may refer to a refiner plate segment 105, a crusher rib segment 105 having an integral refining portion 175 and a crusher rib portion 134 (see FIG. 2A)_b(see fig. 3A) and a refiner plate segment comprising a refining section 175 but lacking a crusher ridge portion 134. Having outer refiner plate segments 105_aAnd crusher edge segment 105_bIn the embodiment of (1), the outer refiner plate segment 105_aAn integral refining section 275 (fig. 2A) and crusher ridge portions 234 may still be included. However, the outer refiner plate segment 105_aUpper crusher arris 125 is generally smaller than the crusher arris section 105_bUpper breaker edge 125. When mounted on the backing assembly 174, the breaker rib segments 105_bFrom the outside refiner plate segment 105_aDisposed radially inward.

In the active mechanical refiner 100, feed 147 (fig. lB), which may be a lignocellulosic feed (typically in the form of wood chips), flows through an opening 181 in the center of the stator refining assembly 102 before encountering the rotor hub 186 or rotor thrower 187. The rotor refining assembly 101 typically rotates in the range of 900 to 2, 300rpm about the center of rotation C (fig. 1B) to throw the feed 147 radially outward into the gap 449. Where the feed 147 further flows through the gap 449 and across the opposed refiner plate segment 105_aAnd 105_aThe crusher bars 125 may crush the feed material 147 before the refining segments 175 defined by the upper alternating refining bars 130 and refining grooves 141. The refined and partially ground material 147' exits the mechanical refiner 100 through an outlet 188. The operator may then sift the refined material from the partially ground material and transfer the partially ground material to a second stage refiner. In addition to or instead of further refining the partially ground material, an operator may process the partially ground material.

Further, although not depicted, it is to be understood that the exemplary refiner plate segments disclosed herein may also be configured for use in a conical mechanical refiner. It will also be appreciated that the exemplary refiner plate segments disclosed herein may also be configured for use in disc-cone mechanical refiners that include flat disc surfaces and conical surfaces. Other types of mechanical refiners 100 compatible with the disclosed refiner plate segment 105 include, but are not limited to, counter-rotating refiners that include two counter-rotating rotor assemblies 101 and multi-component refiners that include multiple refining components (see 101 and 102).

The operator typically adds dilution water (see 245, figure 2) to the mechanical refiner 100 along with the feed 147. Once the feed 147 is sufficiently separated in the refining section 175, the dilution water is combined with the feed 147. The dilution water is free flowing and typically includes a majority of the free water 245 that flows through the gap 449. When the feed 147 is lignocellulosic material or other biological material containing trapped water, the mechanical refining also releases the trapped water, which contributes slightly to the amount of free (liquid) water 245 in the system.

Applicants have developed refiner plate segments having a variable base profile 210 (fig. 2B) as more fully described in U.S. patent No. 6,616,078. The variable base profile 210 successfully facilitates distribution of the feed material into the refining section 175, improves control of feed material strength, and reduces negative interaction between the return steam and the feed material 147. However, without being limited by theory, applicants believe that the variable base profile 210 also directs the free water 245 through the gap 449 at a substantially constant radial position (see RP)₁Fig. 4B), which results in cavitation erosion on the opposing refiner plate segment 105'. To address this problem, applicants incorporate a water channel 250 according to the present disclosure.

Fig. 2A shows an exemplary rotor refiner plate segment 205 having water channels 250 disposed in the crusher ridge portion 234. The crusher ridge portion 234 has a variable base profile 210. In the depicted embodiment, the water channel 250, and in particular the channel bottom 253 (fig. 2B) of the water channel 250, is completely exposed to the gap 449. In other words, the depth of the water channel 250 corresponds to the full height of the profile of the protrusion 294, i.e., the water channel 250 cuts through the variable base profile peak 239 (see also fig. 8). Thus, in the embodiment of fig. 2A, the top 658 (fig. 6) of the water channel 250 is not present.

The refiner plate segment 205 includes a base 209, the base 209 has a radial length R L (FIG. 2B) extending from the narrow side 211 to the wide side 213, the wide side 213 being positioned distally from the narrow side 211, the base 209 also includes a first side 217 and a second side 218 disposed distally from the first side 217, the first and second sides 217 and 218 extend along the radial length R L between the narrow side 211 and the wide side 213, the base 209 has a rear surface 212 (FIG. 2B) disposed opposite the front surface 219 along a thickness T of the base, the rear surface 212 and the front surface 219 extend between the wide side 213, the narrow side 211, the first and second sides 217 and 218, a thickness T at the narrow side 211, and₁may be greater than a thickness T disposed distally from the narrow side 211 along the radial length R L₂Is thin. Some refiner plate segments may remove a portion 293 of the base 209, particularly on the rear surface 212, to reduce weight.

The front surface 219 further includes an area 220 defined by the front surface 219 disposed between the narrow side 211, the wide side 213, the first side 217, and the second side 218. In the embodiment depicted in fig. 2A-2D, the portion of the region 220 closer to the narrow side 211 has a plurality of alternating breaker ribs 225 and grooves 227. The "breaker edge" 225 is sometimes referred to by those of ordinary skill in the art as a "feeder edge". The crusher bars 225 crush larger pieces of the feed 247 prior to feeding the feed 247 (fig. 2B) further into the gap 449 for further crusher bars to encounter or for primary refining through the refining section 275. The breaker ribs 225 engage the base 209 and adjacent breaker ribs 225', 225 "define wide slots 227 therebetween. The breaker bars 225 are generally thicker, more widely spaced, and located closer to the center of rotation C than the refining bars 230. The breaker bars 225 and wide slots 227 generally break the lignocellulosic feedstock 247 prior to feeding the lignocellulosic feedstock 247 into the gap 449. When zone 220 includes a breaker edge 225_a、225_cThe region 220 is referred to as a "crusher ledge" 234. When the zone 220 includes refining ribs 230 and grooves 241, the zone 220 is referred to as a "refining section" 275. In certain exemplary embodiments, the refiner plate segment 205 may include a plurality of refining segments 275. During operation, facing, oppositely arranged refiningThe refining section 275 on the machine plate segments 205 (fig. 2A and 2B), 205' (fig. 2C and 2D) rapidly diverts the feed 247 back and forth through the gap 449 to form a dense fiber mat having sufficient frictional and shear forces needed for defibrillation to refine the feed 247.

The refiner plate segment 205 may further include a full surface dam 257, a subsurface dam 237 or both a full height dam 257 and a subsurface dam 237. The full surface dam 257 and the subsurface dam 237 are protrusions provided in the refining groove 241. Each type of dam 237, 257 is disposed generally perpendicular to the length of the adjacent refining edge 230 and may have an inclined leading face disposed closer to the narrow side 211 than a distally disposed trailing face. During operation, the full-face dam 257 and the subsurface dam 237 deflect the feed 247 flowing through the refiner groove 241 into the gap 449. The full-face dam 257 has the same height as the adjacent refining edge 230. The subsurface dam 237 is shorter than the adjacent refining edge 230.

The base 209 also includes a plurality of water channels 250 disposed in the breaker ridge portion 234. The exemplary water channel 250 has a first end 251 disposed closer to the narrow side 211 than a second end 252. Second end 252 is disposed closer to broad side 213. The exemplary water channel 250 is embedded within the substrate 209 and has a channel bottom 253 that is exposed to the gap 449 when the mechanical refiner 100 is in operation. In certain exemplary embodiments (see fig. 6, 7A, 7B, 7C), the substrate 209 may completely surround the water channel 250 (see fig. 6). The water channel 250 has a channel bottom 253 and distally disposed lateral sidewalls 254, 256 extending between the water channel first end 251 and the water channel second end 252.

Without being bound by theory, it is believed that the water channels 250 provide an alternative path for the bulk of the free water 245 entering the mechanical disc refiner 100 when dilution water is released during refining.e., additional free water 245 may come from the seals in the form of condensate.a channel bottom 253 may be flat to allow the free water 245 to flow along the radial length R L of the refiner plate segment 205 without being pushed into the gap 449 separating the opposing refiner plate segment (see 405 and 405').

In other exemplary embodiments, two or more water channels 250 may be radially aligned in the variable base profile 210. The channel first ends 251 may be disposed at the narrow side 211 of the refiner plate segment 205. In other exemplary embodiments, the channel second end 252 may extend to the boundary of the crusher ridge portion 234 and the refining section 275.

The water channel 250 preferably has a depth between half of the variable base profile peak 239 to the full height of the variable base profile peak 239. In this manner, the water channel 250 can be said to have a comparative channel depth, wherein the height between the trough valley 235 and the radially adjacent peak 239 of the variable base profile 210 is the "fully raised profile height," and wherein the comparative channel depth is between one-half of the fully raised profile height and the fully raised profile height.

The peaks 239 serve to deflect the feed 247 to the opposing refiner plate segment 205'. Desirably, the water channels 250 may have a width w of 2 millimeters ("mm") to 5mm to prevent the feed 247, particularly lignocellulosic material, from easily passing through the water channels 250. It will be appreciated that small fine lignocellulosic cellulose particles may flow through the water channels 250.

In other exemplary embodiments, the channel bottom 253 can have a concave curve, in other exemplary embodiments, two or more water channels 250 are radially aligned in the variable base profile 210 (i.e., the water channels 250 are parallel to a radial line extending from the axis of rotation C (FIG. 1B) to the wide side 213 of the refiner plate segment 205 (see R L)). in yet other exemplary embodiments (FIG. 4B), the channel bottom 253 can have a convex curve.

FIG. 2B is a view of the exemplary refiner plate segment 205 of FIG. 2AA cross-sectional profile taken along line a-a. Figure 2B more clearly depicts the base 209 having a variable base profile 210 disposed between the narrow side 211 and the refining section 275 (see also figure 8). The variable base profile 210 includes a first radial position RP on the front surface 219₁A trough valley 235 (fig. 2B) and a second radial position RP on the front surface 219₂Adjacent peaks 239, the front surface 219 connects the trough 235 and the adjacent peaks 239 in an S-shaped curve the trough 235 and the adjacent peaks 239 may repeat along the length of the variable base profile 210 the variable base profile length VSP L is a subset of the radial length R L of the refiner plate segment 205.

In such an exemplary embodiment, the repeating S-shaped curve defines a wave along the variable base profile length VSP L in this manner, the variable base profile 210 is configured to direct the feed 247 through the gap 449 to the opposing refiner plate segment 205 '. if the opposing refiner plate segment 205 ' also has a complementary wave pattern, the opposing refiner plate segment 205 ' will be at a more than first radial position RP₁A second radial position RP disposed further away from the narrow side 211₂Where the feed 247 is directed back to the first refiner plate segment 205. Depending on the number of peaks 239 and troughs 235 in the complementary wave pattern, the feed 247 may be directed back and forth through the gap 449 at further radial positions (e.g., at third, fourth, fifth, sixth, etc. radial positions) disposed sequentially further away from the narrow side 211.

For example, feed 247 at RP₁And RP₂From the rotor refiner plate segment (see 205) depicted in fig. 2B to the stator refiner plate segment (see 205') depicted in fig. 2D, through the gap 449 (see also fig. 4B). Feed 247 at RP₂And RP₃To flow back to the rotor. Without being bound by theory, it is believed that the back and forth transfer of the feed 247 through the gap 449 more uniformly reduces the size of the feed 247 prior to introducing the feed 247 to the primary refiner 275. Since the variable base profile 210 extends annularly around the assembled refiner assembly (see 101, 102), the radial position RP₁、RP₂、RP₃Etc. are sequentially but evenly distributed around the circumference of the front surface 219. Radial position RP₁、RP₂、RP₃The distribution of the like may allow for a better distribution of the feed 247 into the primary refining section 275 with a more uniform size, thereby reducing the energy required to produce the refined material 147' at a particular quality, hi addition, return steam from the refining section 275 flows through the S-shaped gap 449 to the narrow side 211 this return steam thermally softens the incoming feed 247, thereby "preconditioning" the feed prior to refining in the refining section 275 the more uniform size of the feed 247, the improved distribution thereof also results in a more uniform preconditioning of the feed 247 prior to refining in this manner, the variable base profile 210 on the at least one refiner plate segment 205 further promotes a return of an amount of steam sufficient to thermally soften the feed, and, by adjusting the angle θ (fig. 5) of the variable base profile 210 relative to the radial length R L, the variable base profile 210 may better control the angle of the feed entering the primary refining section 275.

Fig. 2C depicts an exemplary stator refiner plate segment 205 'having a variable base profile 210' complementary to the rotor refiner plate segment 205 depicted in fig. 2A. Fig. 2D is a cross-sectional side view of fig. 2C taken along line B-B. A second radial position RP on the rotor refiner plate 205₂Corresponds to a substantially identical second radial position RP on the stator refiner plate segment 205₂At the trough valley 235'. Likewise, a first radial position RP on the rotor refiner plate 205₁Corresponds to a substantially identical first radial position RP on the stator refiner plate segment 205₁Peak 239 at (d). For a third radial position RP₃As well as so. The S-shaped curve connects the peaks 239 and troughs 235 on the stator refiner plate segment 205 'to form a variable base profile 210' having a wave pattern complementary to the variable base profile 210 of the rotor refiner plate 205.

Fig. 2B and 2D are provided as examples. It will be appreciated that not every embodiment according to the present disclosure will have a trough 235 on the stator refiner plate 205 that directly corresponds to the same radial position RP as the crest 239 at a given radial position RP on the rotor refiner plate 205. For purposes of this disclosure, unless otherwise indicatedStated otherwise, the radial position RP is defined relative to a feature on the rotor refiner plate segment 205 or the first rotor refiner plate segment (see 405). It will be appreciated that if the rotor refiner plate segment 205 is at the first radial position RP₁Has a trough valley 235 and is at a second radial position RP₂With the crests 239 ' disposed radially outward, the corresponding crests 239 ' on the stator refiner plate segment 205 ' may be radially disposed at a first radial position RP₁And a second radial position RP₂In the meantime. The same disclosure applies to subsequent radial positions (e.g., RP)₃、RP₄、RP₅、RP₆Etc.).

FIG. 3A depicts an exemplary rotor refiner plate segment 305, wherein the refiner plate segment 305 is a crusher bar segment 305_b(fig. 3B) (see also fig. 8). Crusher arris section 305_bIncludes a base 309 having a radial length R L, the radial length R L has a radial length first end 303 and a radial length second end 307, the base 309 further includes a narrow side 311 at the first end 303 of the radial length R L and a wide side 313 at the second end 307 of the radial length R L_b. Thus, the broad side 313_bFrom narrow side 311 along radial length R L_bDistally located and broad side 313_bNarrower than narrow side 311_bAnd (4) wide. Narrow side 311_bOr broad side 313_bMay further comprise a spacer 316 (see also 216), said spacer 316 being configured to abut the refiner plate segment 305 against other refiner plate segments (see 305) (see also 305)_aFig. 3B) or other guide members in the mechanical refiner 100. Spacer 316 is generally considered to be a broad side 313_bA part of (a).

The base 309 of the refiner plate segment 305 also includes a first side 317 and a second side 318 disposed distally from the first side 317, the first side 317 and the second side 318 are generally along a radial length R L on the narrow side 311_bAnd broad side 313_bExtending therebetween. Fig. 3B is a cross-sectional side view of fig. 3A taken along line C-C. As more clearly depicted in fig. 3B, substrate 309 has a rear surface 312 disposed opposite front surface 319 along a thickness T of substrate 309. The back surface 312 and the front surface 319 are on the broad side 313_bNarrow side 311_bA first side 317 and a second side 318. Narrow side 311_bThickness T of₁May be wider than the side 313_bThickness T of₂Is thin. Crusher arris section 305_bBroad side 313 of_bAdjoining refiner plate segments 305_aNarrow side 311 of_a。

The front surface 319 further includes a region 320 having a plurality of alternating crusher ribs 325 and wide slots 327. The crusher ribs 325 engage the base 309, and adjacent crusher ribs 325 ', 325 "define a wide trough 327 between adjacent crusher ribs 325', 325". The breaker bars 325 are generally thicker, more widely spaced, and located closer to the center of rotation than the refining bars 230.

The refiner plate segment 305 may have several types of bars 230, 325 and grooves 241, 327 for example, when the refiner plate segment is a crusher bar segment 305b, the bars 325 may include transverse bars 325a that extend from the narrow side 311 to the wide side 313 along the radial length R L of the crusher bar segment 305 b.

As the feed 347 moves from the first end 303 to the second end 307 of radial length R L, the outer ridge 325_cAnd a middle edge 325_bIncreasing the rod density on the front surface 319, thereby injecting the feed 347 radially outward into the outer refiner plate segment 305_aThe gaps 449 between break the feed 347 into smaller particles. Because of the outer edge 325_cMiddle edge 325_bAnd transverse edge 325_aAre all arranged at the crusher edge section 305_bUpper, so outer edge 325_cMiddle edge 325_bAnd transverse edge 325_aMay be generally referred to as a "breaker bar" 325.

The exemplary refiner plate segment 305 has a plurality of water channels 350. Desirably, the number of water channels 350 is sufficient to remove a majority of the free water 345 pushed through the gap 449, otherwise such free water 345 will impinge upon the opposing refiner plate segment 305'. Desirably, the number of water channels 350 may be at least as great as towards the crusher rib section 305_bNarrow side 311 of_bExtended transverse breaker edge 325_aAre equal in number. Transverse edge 325_aWithout the need for a crusherThe rib portions 334 extend the entire length thereof, but rather are transverse ribs 325_aOnly the longest edge on the crusher edge part 334 is required. Desirably, the width w of the water channel 350 increases slightly between the first end 351 of the water channel and the second end 352 of the water channel. That is, the water channel 350 has a first width w at a first end 351₁And has a second width w at a second end 352₂. In this manner, the water channel 350 may prevent as many solid particles as possible from entering the water channel 350. It is undesirable to trap too much feed 347 in the water channel 350. In certain exemplary embodiments, the first width w₁Is 0mm (see FIG. 5).

It will be appreciated that the number of exemplary water channels 350 may vary depending on the type of refiner plate segment 305 and the material the refiner plate segment is configured to grind. Moreover, the exact location and size of the water channels 350 may be varied to allow free water 345 to flow radially outward from the refiner plate segment 305 without deflecting an amount of free water 345 onto the opposing refiner plate segment 305 'sufficient to cause cavitation at a fixed radial position on the opposing refiner plate segment 305'.

FIG. 4B depicts opposing rotor breaker bar refiner plate segments 405_b、405_b'. In the depicted embodiment, the first rotor breaker edge segment 405_bThe upper water passage 450 has a convexly curved bottom 453. That is, the first rotor breaker edge segment 405_bUpper water passage at a first radial position RP₁Has a water passage trough 442 and is in a second radial position RP₂Having a water channel peak 433 adjacent to and radially outward of the water channel trough 442. Wherein the water channel bottom 453 connects the water channel trough 442 to the water channel top 433 in a convex curve. Similarly, the second water channel trough 442 is from a second radial position RP₂At a third radial position RP radially outwardly of the water channel crest 433₃To (3). The water passage bottom 453 similarly curves the second radial position RP convexly₂At peak 433 is connected to a third radial position RP₃At the trough 442. However, in the same refiner plate segment 405_bUpper, waterThe channel peak 433 is shorter than the variable basal peak 439. As a result, the water channel peaks 433 are less likely to deflect the free water 445 to a fixed radial position on the opposing refiner plate segment 405', thereby avoiding cavitation problems affecting previous variable base profile designs.

Similarly, FIG. 4B shows a second breaker edge segment 405 with a water channel 450_b', the water channel 450 ' has a concavely curved bottom 453 '. That is, the second rotor breaker edge segment 405_bThe upper water passage 450 ' has a water passage trough 442 ' and a water passage peak 433 ' adjacent to the water passage trough 442 ', wherein the water passage bottom 453 ' connects the water passage trough 442 ' to the water passage peak 433 ' in a concave curve.

Fig. 4B is provided as an example. It will be appreciated that not every embodiment according to the present disclosure will have a water channel trough 442 on the second refiner plate segment 405' that directly corresponds to the same radial position RP as the water channel crest 433 at a given radial position RP on the first refiner plate segment 405. It will be appreciated that if the first refiner plate segment 405 is at a first radial position RP₁Has a water passage trough 422 and is in a second radial position RP₂Having water channel crests 433 disposed radially outward of the water channel trough 442, the corresponding water channel crests 233 'on the opposing refiner plate segment 405' may be disposed radially at a first radial position RP relative to the first refiner plate segment 405₁And a second radial position RP₂In the meantime. The same disclosure applies to subsequent radial positions (e.g., RP)₃、RP₄、RP₅、RP₆Etc.).

Further, while fig. 4B depicts the convex water channel bottom 453 on the first refiner plate segment 405 and the concave water channel bottom 453 ' on the second (opposite) refiner plate segment 405 ', it is to be understood that the curved bottoms 453, 453 ' may be inverted in other exemplary embodiments.

Fig. 4A shows a flat water channel 450 similar to that depicted in fig. 3. Fig. 4A and 4B show a mechanical disc refining configured for use in reverse rotationCrusher arris segment 405 in a machine (see 100)_bIt will be appreciated that the exemplary refiner plate segment 405 may have a combination or variation of the water channels 450 described herein. the flat water channel trough 450 lacks the water channel trough 442 and the water channel crests 433. fig. 4A more clearly illustrates the path of the free water 445 through the water channels 450. the free water 445 flows through the refiner plate segment 405 primarily along the radial length R L, while the variable base profile 410 directs the feed 447 into the gap 449 between the opposing refiner plate segments 405, 405'.

Because of the crusher rib segment 405_bWithout the refining portion 275, the variable base profile 410 may extend the crusher edge segment 405_bR L in other exemplary embodiments, the variable base profile 410 may extend less than the crusher rib segment 405_bR L as described with reference to fig. 2, the front surface 419 of the refiner plate segment 405 repeatedly connects alternating troughs 435 and crests 439 with an S-shaped curve to define a wave along the length VSP L of the variable base profile, the S-shaped curve rising from the trough 435 may direct an incoming feed 447 through the gap 449 toward the opposite refiner plate segment 405'₁A second radial position RP located further away from the narrow side 411₂Where the feed material 447 is directed back to the first refiner plate segment 405 depending on the number of peaks 439 and troughs 435 in the complementary wave pattern, the feed material 447 may be directed back and forth through the gap 449 at further radial positions (e.g., at third, fourth, fifth, sixth, etc. radial positions) disposed sequentially further away from the narrow side 419.

FIG. 5 depicts an exemplary rotor breaker edge segment 505 for a mechanical refiner 100_b. Depicted crusher edge segment 505_bWith curved breaker edges 525 and water channels 550. Water (W)The channels 550 may be disposed at an angle θ relative to the radial length R L of the refiner plate segment 505-including lateral angles, vertical angles, and combinations thereof FIG. 5 also depicts the opposing refiner plate segment 505' in phantom.

Although depicted generally linearly, it is understood that the exemplary water channel 550 can be convexly curved, concavely curved, or have an S-shaped curve along the variable substrate profile length VSP L, including in a lateral, vertical direction, or a combination thereof.

Fig. 6 depicts an exemplary water channel 650 disposed entirely within the substrate 609 such that only the water channel first and second ends 651 and 652 are exposed to the process. As a result, substrate 609 further defines channel top 658. Height ch of water channel second end 652₂May be greater than the height ch of the water channel at the first end 651₁. In other exemplary embodiments, the water channel height may be substantially constant. It is contemplated that by making the first end 651 of the water channel 650 smaller than the second end 652 of the water channel, the water channel 650 will be less likely to receive the feed 647 and more likely to allow the free water 645 to flow through the water channel 650 without passing through the gap 449.

Fig. 7A is a front view of a narrow side 711 and a plurality of water channels 750 disposed within a base 709, the water channels 750 having a first end 751 and a second end 752 that are exposed to the process (fig. 7C). The first end 751 may have a shape selected from any shape, including circular, elliptical, quadrilateral, polygonal, or rounded rectangular. A plurality of water channels 750 may be disposed within a portion of the base 709 that defines a wavelength between two adjacent trough valleys 635, 635'. If the water channel first end 751 is disposed closer to the narrow end 711 than the second end 752, a plurality of water channels 750 may be randomly arranged within the base 709. Likewise, in other exemplary embodiments, the plurality of water channels 750 may be arranged in an ordered manner. In certain exemplary embodiments, each of the plurality of water channels 750 extends through a base 709 (see fig. 2A) having a water channel first end 751 aligned with a water channel second end 752.

Fig. 7B is a cross-sectional view of fig. 7A taken along line D-D. Fig. 7B depicts another exemplary embodiment wherein a water channel 750 has a plurality of first ends 751, 751 'and a second end 752 less than the plurality of first ends 751, 751'. In the depicted embodiment, the plurality of first ends 751 are smaller than the second ends 752, desirably preventing the lignocellulosic feedstock 747 from entering the water channel 750, while allowing the free water 754 to enter the water channel 750.

FIG. 7C illustrates an exemplary second end 752 of the water channel 750. the second end 752 of the water channel 750 may have a different shape than the first end 751 of the water channel 750, regardless of whether the water channel 750 merges along the radial length R L of the base 709. in embodiments where the single water channel first end 751 aligns with the single water channel second end 752, a manufacturer may create the water channel 750 by drilling into the base 709 of the variable base profile 710. alternatively, a manufacturer may choose to create the water channel 750 using additive manufacturing techniques, such as three-dimensional ("3D") printing techniques.

FIG. 8 is an exemplary breaker edge segment 805_bIs shown in perspective view. As can be more clearly seen from this perspective, the variable base profile 810 throws the feed 847 from the front surface 819 to the opposing refiner plate segment 405_b' (FIG. 4B). In contrast, the water passages 850 allow free water 845 to pass through the variable base profile 810 without being directed toward the opposing refiner plate segment 405_b' through gap 449.

Suitable three-dimensional printing techniques include selective laser sintering ("S L S"), direct metal laser sintering ("DM L S"), electron beam melting ("EBM"), binder jetting ("BJ"), and material jetting ("MJ")/wax casting.

In the S L S technique, a manufacturer directs a laser (typically a pulsed laser) at a source of sinter powder material to selectively fuse small particles of metal into a mass having a desired cross-sectional shape of the finished product.

The DM L S technique is similar to the S L S technique except that the powder is a metal or metal alloy of the desired product and the laser completely melts the powder rather than just the binder.

EBM technology is similar to the DM L S process except that manufacturers use an electron beam as the primary energy source rather than a laser.

In BJ technology, an inkjet print head is moved across a powder bed and selectively deposits an adhesive or other binder into the powder bed in the cross-sectional shape of the finished article. After depositing a layer of binder, an additional layer of powder is deposited and the printhead continues to print the next cross-sectional shape. In this way, the manufacturer can build a three-dimensional product from the powder bed. It is contemplated that a manufacturer may print sand molds with solid tendrils using the BJ method, where the exemplary water channel 750 would be located on the finished refiner plate segment 705. The manufacturer may then introduce molten metal into the sand mold to create the exemplary refiner plate segment 705. Upon cooling, the manufacturer may physically or chemically break down the sand mold to expose the refiner plate segment 705. If any remaining sand occupies the subsurface water channel 750, the manufacturer can chemically dissolve the binder and purge or vacuum the resulting free sand.

It is understood that combinations of embodiments disclosed herein, including combinations of embodiments described with reference to fig. 2A, 2B, 2C, 2D, 3A, 3B, 4A, 4B, 5, 6A, 6B, 7A, 7B, and 8, are considered to be within the scope of the present disclosure.

An exemplary method of manufacturing a refiner plate segment having water channels disposed between a narrow side of a refiner plate and a refining section and having a variable base profile, the method comprising: water channels are created in the variable substrate profile using additive manufacturing techniques, the first ends of the water channels being disposed closer to the narrow side than the second ends, the water channels being disposed in the substrate below the front surface. An exemplary method of manufacturing may further include creating water channels within the substrate using additive manufacturing techniques without drilling. In an exemplary method of manufacturing, the additive manufacturing technique may be selected from the group consisting of selective laser sintering, selective laser melting, electron beam melting, binder jetting, and material jetting.

Another exemplary method of making a refiner plate segment having water channels disposed between the narrow side of the refiner plate and the refining section and having a variable base profile, the method comprising: printing a sand mold for the refiner plate segment using an additive manufacturing process, wherein the sand mold has a region defining a void in the shape of the refiner plate segment having a variable base profile, and the sand mold has a protrusion extending into the region that will define the void of the variable base, the protrusion configured to define a water channel when the refiner plate segment is cast in a mold; and removing the protrusion from the cast refiner plate segment to define a water channel.

An exemplary refiner plate segment for a mechanical refiner comprising: a substrate having: a radial length disposed on a narrow side of a first end of the radial length; a broad side disposed at a second end of the radial length, the broad side positioned radially away from the narrow side along the radial length, the wide side being wider than the narrow side, a first side extending along a radial length between the narrow side and the wide side, a second side extending along the radial length between the narrow side and the wide side, the second side being distally disposed from the first side, and a rear face disposed opposite the front face along the thickness, the rear face and the front face extending between the wide side, the narrow side, the first side and the second side, wherein the front face further comprises a region having a plurality of alternating breaker ribs and wide grooves, wherein the breaker ribs engage the base and adjacent breaker ribs and base define the wide grooves between adjacent breaker ribs, wherein the substrate further comprises a variable substrate profile disposed between the broad side and the narrow side, the variable substrate profile comprising: a trough at a first radial position on the front face, an adjacent crest at a second radial position on the front face, wherein the front face connects the trough and the adjacent crest, and wherein the base further comprises a water channel having a first end disposed closer to the narrow side than a second end.

Exemplary embodiments may further include a comparative channel depth, wherein the height between a trough valley and an adjacent peak of the variable base profile is a "fully raised profile height," and the comparative channel depth is between one-half of the fully raised profile height and the fully raised profile height.

In an exemplary embodiment, the refiner plate segment may have a first end of the water channel with a first end width between 2 mm and 5 mm.

In an exemplary embodiment, the refiner plate segment may have: a first end of the water channel having a first width, a second end of the water channel having a second width, wherein the second width is greater than the first width. In an exemplary embodiment, the base sidewall extends linearly between a first end and a second end. In yet another exemplary embodiment, the first end of the water channel has a first height and the second end of the water channel has a second height, wherein the second height is greater than the first height.

The refiner plate segment may have one or more water channels disposed in the base. The first end of the water passage may have a shape selected from the group consisting of a circle, an ellipse, a polygon, a quadrangle, and a rounded rectangle. The exemplary water channels may merge along the radial length of the refiner plate segment such that the merged water channels have more first ends than second ends.

A refiner plate segment having exemplary water channels may have water channels that further include a water channel trough at a first radial position on the channel bottom and an adjacent water channel crest at a second radial position on the channel bottom, wherein the channel bottom connects the water channel trough and the adjacent water channel crest with a straight line, a concave curve, a convex curve, or an S-shaped curve.

The variable base profile of the exemplary refiner plate segment may form a transverse wave shape. In other exemplary embodiments, the water channel bottom is shaped as a transverse wave.

The exemplary water channel may further include a plurality of water channel troughs alternating between a plurality of water channel peaks, each water channel peak adjacent to at least one water channel trough.

An exemplary refiner plate segment having a variable base profile may have a variable base profile further including a plurality of troughs alternating between crests, each crest being adjacent to at least one trough.

An exemplary water channel is defined by the substrate. The base may define a water channel having a channel bottom disposed in the base below the front face of the refiner plate segment and a distally disposed base sidewall extending between a water channel first end and a water channel second end.

An exemplary mechanical refiner comprising: a first refining assembly having a center of rotation on an axis and configured to rotate about the axis, and a second refining assembly facing the first refining assembly, wherein the first and second refining assemblies each comprise: a backing structure and a plurality of refiner plate segments annularly arranged and fixedly joined to the backing structure, the refiner plate segments having: a substrate, comprising: a radial length, a narrow side disposed at a first end of the radial length, a wide side disposed at a second end of the radial length, the wide side positioned radially away from the narrow side along the radial length, the wide side being wider than the narrow side, a first side extending along the radial length between the narrow and wide sides, a second side extending along the radial length between the narrow and wide sides, the second side being a back surface disposed distally from the first side disposed opposite the front surface, the back and front surfaces extending between the wide, narrow, first and second sides, the back surface being disposed on a backing structure, wherein the front surface further comprises a region having a plurality of alternating refining ribs and grooves, wherein the refining ribs engage the substrate, and wherein adjacent ribs and refining substrate define grooves between adjacent refining ribs, wherein the region of alternating refining ribs and grooves is referred to as a "refining section", wherein the base further comprises a variable base profile disposed between the refining section and the narrow side, the variable base profile comprising: a trough at a first radial position on the front surface, an adjacent crest at a second radial position on the front surface, wherein the front surface connects the trough and the adjacent crest, and wherein the base further comprises a water channel having a first end disposed closer to the narrow side than a second end.

Exemplary mechanical refiners may be selected from the group consisting of rotor-stator refiners, counter-rotating refiners, dual-disc refiners, disc-cone refiners, and cone refiners.

Another exemplary refiner plate segment for a mechanical refiner comprising: a substrate having: a radial length disposed on a narrow side of a first end of the radial length; a wide side disposed at a second end of the radial length, the wide side positioned radially away from the narrow side along the radial length, the wide side being wider than the narrow side; a first side extending along a radial length between the narrow side and the wide side; a second side extending along a radial length between the narrow side and the wide side, the second side disposed distally from the first side; a back surface spaced a thickness from the front surface, the back surface and the front surface extending between the broad side, the narrow side, the first side and the second side, wherein the front surface further comprises a zone having a plurality of alternating refining bars and grooves, wherein the refining bars engage the substrate, and wherein adjacent refining bars and substrates define grooves between adjacent refining bars, wherein the zone of alternating refining bars and grooves is referred to as a "refining section", wherein the substrate further comprises a variable substrate profile disposed between the refining section and the narrow side, the variable substrate profile comprising: a trough at a first radial position on the front surface, an adjacent crest at a second radial position on the front surface, wherein the front surface connects the trough and the adjacent crest in an S-shaped curve, and wherein the substrate further comprises a water channel having a first end disposed closer to the narrow side than a second end disposed closer to the wide side, the substrate defining a water channel having a channel bottom and a distally disposed substrate sidewall extending between the water channel first end and the water channel second end, the channel bottom disposed within the substrate below the front surface.

The exemplary refiner plate segment may further include a crusher bar disposed between the narrow side and the refining section, wherein the base further includes a plurality of water channels.

While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the invention.