DESC:
FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

A SINGLE SETUP REFINER DISC MANUFACTURING METHOD AND REFINER DISC MADE OF SAID METHOD THEREOF

PARASON MACHINERY (INDIA) PRIVATE LIMITED

AN INDIAN COMPANY HAVING ADDRESS AT
GOLDEN DREAMS, E-27, 4TH FLOOR CHIKALTHANA, MIDC, AURANGABAD, MAHARASHTRA INDIA, 431006

THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE SUBJECT MATTER AND THE MANNER IN WHICH IT IS TO BE PERFORMED.

FIELD OF INVENTION
The present disclosure relates to the field of refining equipment, and more specifically, to equipment used in refining of the pulp for paper.

BACKGROUND OF THE INVENTION
Conventional refiner discs are typically manufactured using casting, welding, or milling processes. Refiner discs produced through casting tend to be bulky and require a draft angle to eject them from the casting mold. Further, said draft angle increases the thickness of the rib, which reduces the cutting-edge length and the overall material processing surface of the refiner disc, ultimately decreasing the efficacy and efficiency of the refining process.
In contrast, refiner discs manufactured through the milling process can be designed without a draft angle, allowing for the intended cutting-edge length with the fine bar or micro-fine bar features in order to increase the refining surface. However, this process requires intensive machining of grooves and ribs, which significantly raises the machining cost and increases the complexity of articulating the refiner disc. This complexity leads to a higher product rejection rate and further escalates the cost of said refiner disc.
Moreover, in welded refiner discs, the disc is composed of multiple components, including ribs, tiles, and a base plate. A plurality of ribs are configured with the tiles, and these tiles are then assembled onto a single base plate to form the welded refiner disc. The configuration of numerous ribs within the tiles requires the creation of an equal number of grooves in the tiles, demanding precise machining to ensure a robust and rigid configuration. This precision further increases the machining cost of the tiles.
The machining becomes even more intricate when the ribs and grooves are profiled or curved, leading to higher machining costs and an increased rejection rate. Manufacturing flaws such as profile unevenness, groove uniformity issues, and tile integrity problems become more common if said grooves are not machined in a single machining setup. Additionally, said grooves must be machined to produce a uniform bottom surface opposite to the rib and tile configuration to ensure an intact assembly with the base plate.
The complexity is further heightened when flow restrictors need to be integrated into the refiner disc, wherein the separate grooves must be machined into the tiles in order to accommodate the flow restrictor, which adds to the overall complexity and cost for said refiner disc. Further, said flow restrictor must be designed to facilitate streamlined and effective slurry refining without causing blockages or choking between the paired refiner discs. An inappropriate design or configuration of said flow restrictor can increase the refining load, leading to higher power consumption and reduced refiner disc life.
In another embodiment, precise grooves must be machined for said flow restrictor in accordance with the slurry flow across said refiner disc. This further increases machining time, rejection rates, and profile complexity in order to dramatically driving up the manufacturing cost of said welded refiner disc with said flow restrictor. If not properly designed, said flow restrictor may cause unintended refining loads or blockages, reducing the efficiency and increasing the cost of the pulp refining and overall paper-making process.
Thus, a technological gap exists that needs to be addressed through the development of effective manufacturing methods for said refiner discs.
SUMMARY OF THE INVENTION
In an embodiment, the present disclosure provides a refiner disc comprising a base plate, a plurality of ribs, and a tile. Said plurality of ribs is configured with said tile, and said tile is further configured with said base plate to collectively form said refiner disc. Said tile features a plurality of grooves formed across the surface, which are parallel to each other and designed to accommodate said plurality of ribs wherein said grooves include multiple exits, which are articulated in a configuration selected from a range of patterns which includes but not limits to step-up, step-down, curved, inclined, inline, up-down, spiral, and various combinations thereof. Said grooves are created using a single setup of machining tools, which includes but not limits to options such as a drilling machine, CNC machine, laser drilling, wire cutting, etc., or combinations thereof.
In an embodiment, the present invention provides a refiner disc wherein the through groove includes an exit configured to allow secure insertion and locking of the rib and flow restrictor into the tile.
In another embodiment, the present invention provides a refiner disc wherein the grooves are parallel and evenly spaced across the tile surface to ensure uniform distribution of ribs.
In further embodiment, the present invention provides a refiner disc wherein the grooves are machined with precise dimensions to ensure a tight fit for the ribs, maintaining the structural integrity of the refiner disc.
In furthermore, embodiment, the present invention provides a refiner disc wherein the ribs are secured within the grooves by a process that includes hammering or pressing or press fit to achieve an tight fit.
In still another embodiment, the present invention provides a refiner disc wherein said tiles configured with said rib are locked together using a plug and socket type locking mechanism, wherein one tile includes a protruding plug and an adjacent tile includes a corresponding socket.
In yet another embodiment, the present invention provides a refiner disc further comprising a flow restrictor inserted into the groove exit on the tile, wherein said flow restrictor projects between adjacent pairs of ribs to control material flow.
In an embodiment, the present invention provides a refiner disc wherein a flow restrictor is inserted from the bottom of a tile and extends to the top surface, locking the tiles and/or positioning said tile in place.
In an embodiment, the present invention provides a refiner disc wherein the edges of the tiles are shaped in a dovetail pattern, where one tile has a trapezoidal projection and the adjacent tile has a corresponding recess.
In an embodiment, the present invention provides a refiner disc wherein the tiles configured with the ribs are secured to the base plate by welding at specific points, creating a strong bond with minimal material stress.
In an embodiment, the present invention provides a refiner disc wherein the base plate includes grooves or recesses to accommodate and hold the interlocked tiles in place.
In an embodiment, the present invention provides a refiner disc wherein the flow restrictor is configured laterally between the ribs to increase the retention time of the material being refined.
In an embodiment, the present invention provides a refiner disc wherein the ribs include specific features, such as slots or notches, that allow secure insertion and stabilization of the lateral flow restrictor.
In an embodiment, the present invention provides a refiner disc wherein the flow restrictor is integrated into the tile and secured to the base plate using welding.
In an embodiment, the present invention provides a refiner disc wherein the grooves and exit grooves on the tile surface are configured in advanced patterns such as stepped, inclined, or curved forms to manage the flow of material in order to produce the intended output from said refiner disc and refiner.
In an embodiment, the present invention provides a refiner disc wherein the grooves are arranged in a spiral configuration to provide a gradual increase in refining intensity as the material moves outward.
In yet another embodiment, the present invention provides a refiner disc wherein the flow restrictor includes concave and convex designs to fine-tune the flow of material between the ribs and generate specific refining effect.
In still another embodiment, the present invention provides a refiner disc wherein the grooves and flow restrictor patterns are configured in variations such as inline, step-up, step-down, and spiral patterns.
In yet another embodiment, the present invention provides a refiner disc wherein the spiral angle of the grooves is in the range of 160 to 175 degrees, optimized for a smooth increase in refining load.
In an embodiment, the present invention provides a refiner disc wherein the spiral flow restrictor is designed to minimize turbulence and ensure a consistent refining force across the material being processed.
OBJECT OF THE INVENTION
Some of the objectives of the present disclosure, which are satisfied by at least one embodiment herein, include:
• The main objective of the present disclosure is to manufacture a tile for a refiner disc in a single machining setup.
• Another objective of the present disclosure is to perform the groove manufacturing operation without removing or uplifting the machining tool from the groove to manufacture all grooves required to manufacture across the tile or refiner disc in a single setup.
• Another objective of the present disclosure is to facilitate a refiner disc with a single exit groove and to configure a flow restrictor with the refiner disc in order to maintain a continuous machining profile.
• The other objective of the present disclosure is to design the refiner disc in order to accommodate the tile simultaneously with the rib and flow restrictor in order to enhance the integrity.
• Further, the objective of the present disclosure is to provide a robust configuration for said rib with said tile configuration by means of tight fit. Furthermore, the objective of the present disclosure is to facilitate the smooth and streamlined surface to configure the configuration of said tile and said rib with said base plate.
• Still another objective of the present disclosure is to facilitate the possibility of the variety of flow restrictor and exit groove configuration.
• Still another objective of the present disclosure is to formulate a robust and rigid refiner disc by locking or welding the corresponding tiles and welding of said tile and said rib configuration with said base plate.
• Yet other objective of the present disclosure is to include a plurality of refining patterns which include but not limits to the single spiral, dual spiral, and curved pattern type of the exit groove and flow restrictor configuration.
• More objective of the present disclosure is to reduce the manufacturing time and cost for said tile and said refiner disc.
• Still more objective of the present disclosure is to increase the efficiency and efficacy of said refiner disc at low cost and manufacturing time with greater precision.
Other objectives and advantages of the present disclosure will become more apparent from the following description, which is not intended to limit the scope of the present disclosure.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
The foregoing summary, as well as the following detailed description of embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the disclosure, there is shown in the present document example constructions of the disclosure. The detailed description is described with reference to the following accompanying figures.
Figure 1: illustrate a schematic view of a refiner disc;
Figure 2: illustrate a schematic view of a refiner disc and sector ;
Figure 3: illustrate a schematic view of a base plate;
Figure 4: illustrate a schematic view of a refiner disc and sector;
Figures 5 to 7: illustrate various locking mechanisms, such as plug and socket, used to secure tiles together;
Figures 8-9: illustrate different aspects of refiner disc segments with double and single mounting;
Figure 10: illustrate the different configurations of exit grooves between the grooves;
Figure 11: illustrates the use of a flow restrictor;
Figure 12: illustrate the different configurations of a flow restrictor corresponding to figures 10a, 10b, 10c, and 10(e-g);
Figure 13: illustrates another embodiment of the tile surface's design configuration;
Figure 14: illustrate the V-shaped exit groove;
Figure 15: illustrates another embodiment of the tile design configuration of the refiner disc;
Figure 16: illustrate the pattern formed by the grooves and exit grooves on the slightly angled sector;
Figures 17-: illustrate the configuration of a ribs with a groove;
Figures 18: illustrate the configuration of a ribs with a flow restrictor configuration provision; Figure 19a -19b: illustrate the multiple flow restrictor configuration ;
Figure 20a-20b: illustrates a single spiral exit groove configuration for a refiner disc ;
Figure 20c: illustrates a single spiral flow restrictor configuration with local flow restrictor for said refiner disc;
Figure 20d: illustrates a single spiral flow restrictor configuration without local flow restrictor for said refiner disc;
Figure 21a: illustrates a dual spiral exit groove configuration for a refiner disc;
Figure 21b: illustrates an aletrnate or zig zag pattern of the dual spiral type exit groove configuration for said refiner disc;
Figure 21c: illustrates a dual spiral flow restrictor configuration without local flow restrictor for said refiner disc;
Figure 21d: illustrates a dual spiral flow restrictor configuration with local flow restrictor for said refiner disc;
Figure 22a: illustrates a curved pattern exit groove configuration for a refiner disc;
Figure 22b: illustrates a curved pattern flow restrictor configuration for sector of said refiner.

LIST OF REFERENCE NUMERALS
Reference numeral References associated with reference numeral
Numeral Particular
100 Refiner disc
101 Exit groove
102 Groove
103 Surface of the disc
104 Rib
105 Flow restrictor
200 Refiner disc
201 Exit Groove
202 Groove
203 Surface of tile
204 Ribs
205 Tiles
206 Locking
207 Sector
208 Segment
300 Base Plate
301 Welding for fixing segments
400 Refiner disc
401 Grooves
402 Exit grooves
403 Valley
404 Rib
501,601,701 Protruding plug
502,602, 702 Socket
503, 603, 703 Tiles
504, 604, 704 Exit grooves
505, 605, 705 Grooves
505a, 605a, 705a End groove
505b, 605b, 705b Entry groove
506a, 506b, 606a, 606b, 706a to 706f Sector or group
507, 607, 707 Edge
801, 901 Tile
801a, 901a Sector
802, 902 Grooves
803 Double mounting
903 Single mounting
1001a—g, Exit grooves
(1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga) Groove
(1001ab, 1001bb, 1001cb, 1001db, 1001eb, 1001fb, 1001gb) Channels
1100 Exit grooves
1101 Flow restrictor
1102 Rib
1103 Tile
1104 Rib
1301 Groove
1302 Exit groove
1303 Tile
1304 Edge
1305 Centre
1402 V-shape exit groove
1501 Exit groove
1500a, 1500b Sectors
1502a End groove
1502b Entry groove
1503 Tile
1601 Exit groove
1602 Grooves
1600a,1600b Sectors
1603 Tile
1701 Rib
1701a, 1701b Slot
1702 Groove
1703 Tile
1801 Rib
1802 Locator
1900 Flow restrictors
1900a to 1900k Flow restrictors
1901ba and 1901ca Notch
1901da, 1900ea and 1900fa Bottom extension
1900db, 1901eb and 1901fb Top side
1901ga, 1901ha, 1901ia, 1901ja and 1901ka Escape
2000 Refiner disc
2000a to 2000l Sectors
2001 Exit grooves
2001a Local exit grooves
2002 Grooves
2003 Tiles
2004 Rib
2005 Spiral
2005a First spiral
2005b Second spiral
2006 Input end
2007 Output end
2008 Flow restrictor
2008a Local flow restrictor
2100 Refiner disc
2100a to 210l Sectors
2101 Exit grooves
2101a Local exit grooves
2102, 2102a Grooves
2103 Tiles
2104 Rib
2105 Spiral
2105a First spiral
2105b Second spiral
2105c Third spiral
2105d Fourth spiral
2106 Input end
2107 Output end
2108 Flow restrictor
2108a Local flow restrictor
2109 Alternate or zigzag pattern
2200 Refiner disc
2200a Sectors
2201 Exit grooves
2202 Grooves
2203 Tiles
2204 Rib
2205 Curve
2206 Input end
2207 Output end
2208 Flow restrictor
2209 Ascending pattern
2210 Valley
2211 Start Length
2212 Sector Length
D Distance
P Height
Q Depth
Y Length
X Length
Z Length

DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a refiner disc for papermaking and refining of lignocellulose and other natural and synthetic fibrous materials in the manufacturing of paper, paperboard, fibreboard, molded fiber, etc. and other allied products. In particular, the present invention relates to a single setup refiner disc manufacturing method and the refiner disc produced by this method.
Figure 1 illustrates the homogeneous type of a refiner disc (100), comprising a plurality of grooves (102) articulated on a surface (103) of said disc (100). These grooves (102) extend horizontally along the length (Y) on the surface (103) of the disc (100). The grooves (102) are manufactured in parallel contour, creating a series of narrow channels. Through these channels, a machining tool—selected from the group which include but not limits to a drilling machine, CNC machine, laser operation which include but not limits to laser cutting, laser drilling, wire cutting, etc, or combinations thereof passes. Said disc (100) features an intricate pattern of grooves (102) radiating outward from the center to the edge of said disc (100). Furthermore, as shown in figure 1 the grooves (102) include an exit groove (101), with each said exit groove (101) appearing to form a bridge by means of a exit groove (101) between two consecutive grooves (102). Said exit groove (101) is arranged in such a pattern that the machining tool, after forming one groove (102), can continuously move to form the next groove without interruption. This design ensures that the tool does not need to stop during the groove formation process. The exit groove (101) between the two grooves (102) may be arranged in a zigzag or alternating pattern. It is mandatory to form a single exit groove (101) between every two grooves (102). Particularly, it is illustrated in said figure no. 01 that two exit grooves (101) are arranged between the three grooves (102), with one exit groove (101) positioned at a predetermined distance (D) from the other. This specific arrangement allows for precise control of the machining tool's movement between the grooves, ensuring uniformity and efficiency in the groove formation process. The exit grooves (101) ensure that the tool moves consistently from one groove (102) to the next, maintaining the same cutting depth and shape throughout the process. This prevents variations that could occur if the tool were to stop and start unevenly. The step-up with step-down or zigzag patterns or alternating patterns of exit grooves (101) may be used to control the relative position of each groove (102), ensuring they are evenly spaced and aligned. This precision ensures that all grooves are uniformly distributed across said disc (100). However, after the formation of all of said grooves (102) and said exit groove (101) a rib (104) is configure with said groove (102) and a flow restrictor (105) configure within said exit groove (101).
In an embodiment, as illustrated in Figure 2, a refiner disc (200) can be formulated by configuring a plurality of sectors (207) of the same or similar type, wherein each of said sector (207) comprises multiple parts, which includes but not limits to a plurality of ribs (204) configured with a tiles(205). The configuration of said ribs (204) and said tiles (205) can be integrated with a base plate (300) as shown in figure no. 03. Said ribs (204) extend vertically to achieve a length (X) (as shown in figure no. 19) on top, such that said ribs (204) are confined in said grooves (202) formed on a surface (203) of said tiles (205). Said ribs (204) extend vertically upward from said grooves (202) in a perpendicular direction to the surface (203) with a length (X) from said tiles (205). Additionally, said ribs (204) extend horizontally for a length (Y) along the grooves (201) of said tiles (205) (as shown in figure no. 19).
Further, as illustrated in Figure 2, a refiner disc (200) comprising a plurality of segments (208) configure with the same or similar type of segments (208) configure with each other via locking (206) and said segment (208) can be configured with a plurality of sectors (207) in order to complete said disc (200). Wherein, in one of the embodiments said segment (208) can include at least two sectors (207) in order to configure said segment (208) with each other and a base plate (300) to formulate said disc (200). However, an exit groove (201) manufactured by means of single setup method in order to facilitate the provision to configure a flow restrictor.
In an embodiment figure 3 illustrates the base plate (300), wherein said base plate (300) of the refiner disc (200) provides options for securing said tiles (205) using techniques which include but not limits to fastening, welding, interlocking, etc. Particularly, figure 3 introduces an alternative method for securing said tiles (205) to said base plate (300) by welding (301). Wherein in present invention said welding is a process is executed in a manner said tiles (205) are welded at specific points only with said base plate (300) in order to ensuring a secure configuration without requiring the entire surface to be welded to adversely impact the mechanical properties of the configuring parts by means of producing very wide heat affected zone. This method is particularly useful in scenarios where said tiles (205) need to be fixed in place with minimal movement or where mechanical locking mechanisms alone might not provide sufficient security. In figure 3, the rear view of the base plate (300) is shown with the locations of the welds are indicated. The tiles are initially positioned on said base plate (300), possibly by means of primary mechanical alignment (like dovetail or plug-and-socket locking), and then welded at key points. The welding process involves applying pressure and heat to the specific spots, melting the metal at the contact points, and creating a strong bond as the metal cools and solidifies. The use of welding offers several advantages:
1. Strong Bond: welding creates a very strong bond between said tiles (205) and said rib (204) configuration and said base plate (300), which is critical in high-stress environments like pulp refining.
2. Reduced Material Stress: Since only specific points are welded, there is less overall heat distortion and stress on said tiles (205) and said rib (204) configuration and said base plate (300) compared to full-surface welding with robust configuration of said tiles (205) and said base plate (300).
3. Precision Placement: welding allows for precise placement of said tiles (205) and said rib (204) configuration, ensuring they remain perfectly aligned during the refining process.
In an embodiment, figure 4 illustrates a disc (400) comprising a plurality of grooves (401) made on a tile (403), wherein an exit groove (402) can be articulated between said grooves (401) in order to form a path between said grooves (401) for smooth transit of a machine tool or a laser operation cutting or trimming. Further, the plurality of said exit grooves (402) between said grooves (401) can be configured in a manner to form a plurality of spiral-shaped grooves. The plurality of grooves (401) can be configured to be spaced apart in order to form a channel or valley (403) between said grooves (401) after the configuration of a rib (404) within said groove (401). Whereas said exit grooves (402) may be arranged in a zigzag or alternating pattern. Particularly, a single exit groove is required to be formed between every two grooves.
In an embodiment, figures 5-7 illustrate the versatility and importance of different locking mechanisms in the assembly of said refiner disc (200, 400). These locking mechanisms are essential for maintaining the structural integrity of said refiner disc (200, 400), especially during manufacturing and assembly of a tiles (503, 603, 703). Figure 5 illustrates the plug (501) and socket (502) type locking mechanism, one of the most straightforward and effective methods for securing tiles (503) together. In this mechanism, one tile (503) is equipped with a protruding "plug (501)" while the adjacent tile (503) has a corresponding "socket (502)" or “recess (502)” designed to receive said plug (501). When said tiles (503) are placed next to each other, said plug (501) fits snugly into said socket (502), effectively locking said tiles (503) together.
Figure 6 illustrates the embodiment similar to the locking mechanism as illustrated in figure 5. In this mechanism, any one of the tile (603) is equipped with a protruding "plug (601)" while the adjacent tile (603) has a corresponding "socket or recess (602)” designed to receive the plug (601). When said tiles (603) are placed next to each other, said plug (601) fits snugly into the socket (602), effectively locking the tiles (603) together. However, in Figure 6, the shape of the protruding plug (601) can be of type which include but not limits to pentagonal, hexagonal or trapezoidal or dovetail, whereas the shape of the producing plug (501) as illustrated in figure 5 can be type which include but not limits to rectangular, square or U-shaped. Further, in Figure 7, the shape of the protruding plug (701) can be of type which include but not limits to elliptical, semi-circular, curved or circular, etc. These different configurations of the plug (501,601,701) allow for various locking mechanisms, enhancing the versatility and application of said tiles (503, 603, 703). Correspondingly, said sockets (602, 502, 702) are designed to match the shape of their respective plugs (501, 601, 701), ensuring a secure and precise fit for each configuration.
Figures 5-7 illustrates a fascinating pattern of grooves (505,605,705) wherein each of said grooves (505, 605, 705) has evenly spaced and parallelly running along the length of said tiles (503, 603, 703) in order to perform uniform homogeneous refining of inputted material. Whereas a machining tool can enter into said tile (503, 603, 703) in order to commence the drilling operation of said grooves (604, 504, 704, 505, 605, 705) from an entry groove (505b, 605b, 705b) positioned with respect to any of the edge (507, 607, 707) of said tile (503, 603, 703) and/or said sector (506a, 606b, 706f), where said machining tool breaks said edge (507, 607, 707) in order to manufacture first groove called said entry groove (505b, 605b, 705b) of edge (507, 607, 707). Further, said machining operation continues without removing or raising the tool from said grooves (604, 504, 704, 505, 605, 705) till machining of all of said grooves (604, 504, 704, 505, 605, 705) required to make on said tile (503, 603, 703) and/or said sector (506a, 606b, 706f). Further, in case of said grooves (505, 605, 705) divided into two or more groups or sectors (506a, 506b, 606a, 606b, 706a, 706b, 706c, 706d, 706e, 706f) in order to form said tile (503, 603, 703) and/or facilitate specific rib pattern of material flow in order to achieve the specific refining effect on the inputted material with lower power consumption said groups or sectors (506a, 506b, 606a, 606b, 706a, 706b, 706c, 706d, 706e, 706f) can be configured with each other employing at least one end groove (505a, 605a, 705a) manufactured on the opposite edge of said edge (507, 607, 707) with said entry groove (505b, 605b, 705b), said end groove (505a, 606a, 706a) open into corresponding said groups or sectors (506a, 506b, 606a, 606b, 706a, 706b, 706c, 706d, 706e 706f). In one of the exemplary embodiments said end groove (505a) is manufactured in said sector (506b) and opens into the corresponding sector (506a), whereas said end groove (605a) is manufactured in said sector (606a) and opens into the corresponding sector (606b). In another exemplary embodiment said end groove (705a) configured into multi-sector (706a, 706b, 706c, 706d, 706e 706f) wherein said end groove (705a) configure said sectors (706a, 706b, 706c, 706d, 706e 706f) with each other by opening into corresponding sectors (706b, 706c, 706d, 706e 706f), for example, a groove (705a) of said sector (706a) opens in said sector (706b), a groove (705a) of said sector (706b) opens in said sector (706c), a groove (705a) of said sector (706c) opens in said sector (706d), a groove (705a) of said sector (706d) opens in said sector (706e), a groove (705a) of said sector (706e) opens in said sector (706f). Said opening of said end groove (505a, 605a, 705a) into corresponding sectors (506a, 506b, 606a, 606b, 706a, 706b, 706c, 706d, 706e, 706f) ensures the continuous machining of said sector (506a, 506b, 606a, 606b, 706a, 706b, 706c, 706d, 706e, 706f) in order to manufacture said complete tile (503, 603, 703) in single setup error-free manner without removing the machining tool in order to enhance the machining efficiency. Furthermore, at the juncture of said sector (506a, 506b, 606a, 606b, 706a, 706b, 706c, 706d, 706e 706f) a gap can be maintained apart from said end groove (505b, 605b, 705b) in order to allow smooth material and steam flow across the refining surface. However, the exit grooves (504, 604, 704) can be formed within said sectors (506a, 506b, 606a, 606b, 706a, 706b, 706c, 706d, 706e, 706f) in order to serve as connectors between said parallel grooves (505, 605, 705), allowing for flexibility and movement. The exit grooves (504,604,704) are arranged in a radiating pattern from the center of the semi-circular sectors towards the edges of said tile (503, 603, 703). However, said tile (503, 603, 703) allows said exit grooves (504, 604, 704) to act as connectors between said parallel grooves (505, 605, 705) within each sector(506a, 506b, 606a, 606b, 706a, 706b, 706c, 706d, 706e, 706f). Moreover, said exit grooves (504, 604, 704) bridge the gap between the two parallel grooves (505, 605, 705). This bridging is essential for maintaining the structural integrity of the tiles (503, 603, 703) in order to perform cost-effective and error-free manufacturing of said tiles (603, 603, 703) while allowing smooth configuration of a flow restrictor.
Particularly, figures 5-7 illustrate a machining process where said multiple grooves (504, 604, 704) formed in a curved manner. The key innovation lies in the continuous path of the machining tool, eliminating the need for tool retraction and repositioning between each groove (505, 605, 705). This is achieved through the design of an "exit groove" (504, 604, 704) that allows the machining tool to transition smoothly from one groove (505, 605, 705) to the next without interrupting the cutting process. This continuous path optimizes machining efficiency by reducing idle time, minimizing tool wear, and ensuring consistent groove (505, 605, 705) formation while allowing smooth configuration of a flow restrictor in said exit groove (504, 604, 704).
In an embodiment, figures 8-9 illustrate different aspects of refiner plate segments with double mounting (803) and a single mounting (903), respectively. The figures discloses a tile (801, 901) comprising at least one sector (801a, 901a). Said sector (801a, 901a) can be configured with an assembly of grooves (802, 902) integrated with the tile (801, 901) in accordance with any of the embodiments illustrated in Figures 2-7. The configuration of said grooves (802, 902) and said tile (801, 901) can be mounted to a refiner mounting provision (not shown in the figure) using various fastening methods, including but not limited to fastener joints, riveted joints, or other types of mechanical joints.
In an embodiment, figure 10 shows the various configurations of the grooves (1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga) and the exit grooves (1001a, 1001b, 1001c, 1001d, 1001e, 1001f, 1001g) (Figures 10a–10g). The grooves (1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga) manufactured on the surface of the refiner disc (100) or said tile (205, 503, 603, 703, 801, 901) that can be configured with each other in order to formulate a refiner disc (200, 400, 2000, 2100, 2200) and extend horizontally and/or in angled form. These grooves (1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga) are arranged in parallel lines, creating a series of narrow channels (1001ab, 1001bb, 1001cb, 1001db, 1001eb, 1001fb, 1001gb) in order to provide the space for the material flow along the refining surface. Whereas said grooves (1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga) and said exit grooves (1001a, 1001b, 1001c, 1001d, 1001e, 1001f, 1001g) are carefully designed with uniformity in width and depth, ensuring precise material removal during the refining process. In one of the embodiments said grooves (1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga) and said exit grooves (1001a, 1001b, 1001c, 1001d, 1001e, 1001f, 1001g) can be of partial depth in case of one piece or homogeneous type of refiner disc (100) which can be configured to allow top assembly of said ribs (104), whereas in another embodiment said grooves (1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga) and said exit grooves (1001a, 1001b, 1001c, 1001d, 1001e, 1001f, 1001g) can be made through the depth of said tiles (205, 503, 603, 703, 801, 901) in case of the manufacturing of a refiner disc (200, 400, 2000, 2100, 2200) made from the configuration of the plurality of sectors (207, 801a, 901a) and/or segment (208) with said tiles (205, 503, 603, 703, 801, 901) in order to allow top and/or bottom to the top configuration of said ribs (204, 404). However, said grooves (1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga) are mandatorily required to be manufactured on the surface of said refiner disc (100) or said tiles (205, 503, 603, 703, 801, 901) in case of the manufacturing of a refiner disc (200, 400, 2000, 2100, 2200) in order to allow robust configuration of said ribs (104, 204, 404) with said (205, 503, 603, 703, 801, 901) and/or said groove (102) of said surface (103) of said refiner disc (100) to facilitates an even distribution of forces as said disc (100, 200, 400, 2000, 2100, 2200) rotates during operation, which enhances the refining efficiency of said disc (100, 200, 400, 2000, 2100, 2200), whereas said exit grooves (1001a, 1001b, 1001c, 1001d, 1001e, 1001f, 1001g) allows configuration of flow restrictor in order to increase the refining material retention to enhances the refining efficacy of said disc (100, 200, 400, 2000, 2100, 2200).
Further, said exit grooves (1001a, 1001b, 1001c, 1001d, 1001e, 1001f, 1001g) function as transitional pathways between consecutive grooves (1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga) effectively "bridging" two adjacent grooves (1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga). The pattern and alignment of the exit grooves (1001a, 1001b, 1001c, 1001d, 1001e, 1001f, 1001g) are critical to the machining process as they allow the machining tool to move seamlessly from one groove (1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga) to the next without stopping or repositioning. The exit grooves (1001a, 1001b, 1001c, 1001d, 1001e, 1001f, 1001g) are arranged to form a continuous path for the machining tool, whether it is a CNC machine, laser drilling or cutting, or wire cutting apparatus. This continuous design ensures that after forming one groove (1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga), the tool can move fluidly to form the next groove (1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga). This seamless progression minimizes tool wear, reduces downtime, and increases the overall efficiency of the groove (1001a, 1001b, 1001c, 1001d, 1001e, 1001f, 1001g, 1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga) formation process to increase the refiner disc (100, 200, 400, 2000, 2100, 2200) production at lower manufacturing cost.
Here is a separate explanation for each of the configurations shown in figures 10a-10g regarding the arrangement of the exit grooves (1001a, 1001b, 1001c, 1001d, 1001e, 1001f, 1001g) between the vertical grooves (1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga):
Figure 10a: In this configuration, said exit grooves (1001a) are manufactured in parallel grooves (1001aa), extending along the surface. Wherein said exit groove (1001a) is positioned between two consecutive vertical grooves (1001aa). This configuration highlights a simple, direct connection between the grooves (1001aa), allowing the machining tool to travel from one vertical groove (1001aa) to the next groove (1001aa) in a straight line. The alignment of said exit groove (1001a) ensures minimal deviation, making the tool's transition smooth and efficient without disrupting the machining process.
Figure 10b: In this figure, said grooves (1001ba) maintain the same parallel vertical alignment, but said exit groove (1001b) is slightly offset between two adjacent vertical grooves (1001ba). This offset design allows the tool to exit one groove (1001ba) and enter the next groove (1001ba) at a slight angle, providing flexibility in tool movement. This arrangement accommodates machining processes where slight angular movements are preferred, enabling smooth transitions with minimal tool repositioning.
Figure 10c: This configuration shows a variation where the grooves (1001ca) are positioned closer together, creating a denser arrangement or a curved bar type of configuration of said grooves (1001ca) required in order to achieve a specific application-oriented refining effect. The exit groove (1001c) can be designed with a concave shape, curving inward between the two consecutive vertical grooves (1001ca) ideal for applications where space is limited, and the grooves (1001ca) need to be packed tightly or designed in curved manner. This design ensures continuous tool movement while still allowing the machining tool to navigate between closely spaced or designed curved manner grooves (1001ca) efficiently.
Figure 10d: Further. said grooves (1001da) remain vertically aligned, but the exit groove (1001d) features a convex shape, curving outward between the adjacent vertical grooves (1001da). This convex design ensures the machining tool travels along an outwardly curved path, providing a broader exit route before moving into said next groove (1001da). This configuration accommodates scenarios where a wider or more expansive transition between grooves (1001da) is necessary, ensuring uninterrupted machining.
Figure 10e: In this configuration, the exit grooves (1001e) are angled slightly between the vertical grooves (1001ea). This design allows the tool to move diagonally as it exits one groove (1001ea) and enters another. Such a configuration is useful in machining processes that require variable angles between grooves (1001ea), allowing for more complex disc patterns and diverse machining strategies.
Figure 10f presents an arrangement where multiple grooves (1001fa) are intersected by a series of exit grooves (1001f), forming a continuous pattern. Said exit grooves (1001f) are characterized by a wave-like or curving form in the middle and appear as slanted or angular bridges, providing multiple options for tool exit. In this figure, the grooves are also configured in slanted or angled direction. This layout is particularly useful when the tool needs to transition between several grooves (1001fa) in quick succession, maintaining efficiency and minimizing unnecessary stops or delays.
Figure 10g: In this figure, the grooves (1001ga) are spaced wider apart, and the exit groove (1001g) exhibits an undulating shape, characterized by a wave-like or curving form from the middle. This undulation provides a dynamic transition path for the machining tool, allowing it to follow a more intricate path between the two consecutive grooves (1001ga). Additionally, the exit groove (1001g) is positioned at a sharp angle, which ensures that the machining tool exits one groove (1001ga) and transitions to the next in a precise and efficient manner. This sharp-angled, undulating design is particularly useful in maintaining continuous tool movement while accommodating more complex groove (1001ga) transitions.
In another embodiment, figure 11 illustrates the configuration of a flow restrictor (1101), wherein said flow restrictor (1101) can be inserted into an exit groove (1100) on the tile (1103) made between the ribs (1102) and projects between two adjacent ribs (1102). Said flow restrictor (1101) serves a dual purpose: it strengthen the configuration of said tiles (1103) and said rib (1102) and also plays a role in controlling the flow of material between the ribs, thereby increasing the retention time of the material and improving the refining quality. Particularly, said flow restrictor (1101) is inserted from the bottom of the tile and extends upwards to the top surface, where it confined in said exit groove (1100) made on said tiles (1103) between said ribs (1102) in a manner to block the channel (1104) completely or at least partially in or order to strengthen the configuration of said tile (1103) and said rib (1102) as well as blocking of said channel (1104) increases the retention time of the material and improving the refining quality in order to enhance the refining process by controlling the flow of pulp through the refiner disc (100, 200, 400, 2000, 2100, 2200).
In an embodiment, Figure 12 (a-d) illustrates the different configurations of the flow restrictor (1100) corresponding to figures 10a, 10b, 10c and 10 (e-g).
Figure 12a: In this configuration, the flow restrictor is angled diagonally, forming a slanted structure that extends between two adjacent groove (1001ba) of said groove exit (1001b). This diagonal design helps restrict the flow of material at an angle, effectively increasing resistance and retention time as the material flows between said grooves (1001ba). It corresponds to Figure 10b, where the grooves (1001ba) are arranged in parallel, and the exit grooves (1001b) are slanted aligned to allow for continuous tool movement.
Figure 12b: This figure presents a concave flow restrictor that curves inward, forming a semi-circular shape between the adjacent grooves (1001ca). The concave form allows for a controlled, smooth flow of material while still enhancing retention time within the grooves (1001ca). The curve shape also increases the structural strength of the flow restrictor, making it more resistant to wear over time. This configuration corresponds to Figure 10c, where the exit grooves (1001c) provide an curved yet compact transition between consecutive grooves (1001ca).
Figure 12c: Here, the flow restrictor exhibits a similar convex shape but on a smaller scale, with a more subtle curvature. This design is particularly effective in maintaining steady flow restriction while allowing material to pass through more efficiently, balancing flow control and retention. This configuration corresponds to Figure 10d, where the grooves (1001da) are more closely spaced, and the exit grooves (1001d) have a compact design. The smaller, more contained flow restrictor shape works well with the tighter groove arrangement.
The concave flow restrictor disclosed in figure no. 10b would create a depression that can hold more pulp and increase the retention time, while a convex design flow restrictor disclosed in figure no. 10c would create a protrusion that restricts the flow more aggressively, potentially enhancing the refining action.
Figure 12d: In this configuration, the flow restrictor is undulating with multiple peaks and valleys, giving it a wave-like or serrated appearance. This complex shape maximizes material retention and flow control by creating multiple points of resistance between the adjacent ribs. It corresponds to Figure (10e-g), where the grooves and exit grooves (1001e, 1001f, 1001g) form a more intricate and variable pattern. The undulating flow restrictor design is ideal for scenarios requiring more complex flow control and increased surface area for refining.
In an embodiment, figure 13 illustrate the staggered pattern of an exit groove (1302) articulated on the surface of the tile (1303). The arrangement of a grooves (1301) in the figure appears to consist of parallel grooves (1301), with exit grooves (also known as transverse grooves) (1302) in between said parallel grooves (1301). Further, said parallel grooves (1301) are spaced at regular intervals, typically around a few feet apart. Said exit grooves (1302), on the other hand, are perpendicular to said parallel grooves (1301) and are spaced at shorter intervals than said parallel grooves (1301). Said exit grooves (1302) are forming a staggered pattern by being offset from each other. Specifically, said exit grooves (1302) on one side of said parallel groove (1301) are not directly opposite the exit grooves (1302) on the other side of the adjacent parallel groove (1301). Wherein firstly said exit groove (1302) follows a continuously downward trajectory from said edge (1304) to a center (1305) of said tile (1303) to stabilize at the said center (1305) by means of at least one straight exit groove (1302), after said exit groove (1302) pattern follows upside trajectory from said center (1305) to other side said edge (1304) of said tile (1303) in order to form the V-shaped pattern of said exit grooves (1302) with central straight groove (1302) cross said center (1305). However, each exit groove (1302) is offset from the one below or above it by approx. half the width of the groove (1301). This creates a staggered or zigzag pattern, where each exit groove (1302) is not directly aligned with the one above or below it. Moreover, said pattern of exit grooves (1302) facilitates the streamlined refining without choking or blocking the material within said vicinity generated after the configuration of the rib within said groove (1301) and a flow restrictor in said exit groove (1302) and during the processing, the refining material between said refiner discs.
In an embodiment, figure 14 illustrates the V-shaped exit groove (1401) pattern without said straight groove (1302) at said center (1305) in order to offer a sharp material retention effect to perform balanced refining process. However, said V-shaped exit groove (1401) can be offset from the one below or above it by approx. half the width of the groove (1301). This creates a staggered or zigzag pattern, where each V-shaped exit groove (1401) is not directly aligned with the one above or below it.
In an embodiment, figure 15 illustrate a tile (1503) with at least two sectors (1500a, 1500b) with intricate groove patterns (1502). Wherein said sector (1500b) can be angled with respect to said sector (1500a) in a manner to provide the different refining patterns from both of said sectors (1500a, 1500b) articulated on a single tile (1503). In one of the embodiments, the angle of inclination of said sector (1500b) can be less than the 45° and preferably in the range of 2° to 40°. Whereas, said sector (1500a) can be configured with said sector (1500b) by means of an exit groove (1501) configured with the end groove (1502a) of said sector (1500a) and the first or entry groove (1502b) of said sector (1500b). Said grooves (1502) are arranged in a systematic, parallel fashion, radiating from the inner edge to the outer edge of the sector in order to perform the homogeneous application-specific refining pattern for said refiner disc.
In an embodiment, figure 16 illustrates a tile (1603) configured with angled sectors (1600a, 1600b) without said exit groove (1501) configuring said sector (1600a) and said sector (1600b). Said configuration of sectors without flow restrictor configuration or said exit groove (1501) facilitates the streamlined material flow channel (1604) in order to provide the high material flow in case specific applications wherein the high material flow is desired. Further, said pattern consists of a series of parallel grooves (1602), evenly spaced and of uniform width and depth, that are cut into the surface of the sector (1600a, 1600b), whereas between each pair of said grooves (1602) said smaller exit grooves (1601) provided in order to connect said grooves (1602). Said exit grooves (1601) are also evenly spaced and of uniform width and depth.
In an embodiment, figure 17 illustrates the cross-sectional view of a rib (1701) configuration with a tile (1702), wherein said rib (1701) can be configured with a tile (1703) in a manner, said rib (1701) can be located over a groove (1702) made on said tile (1703) precisely by means of said slot (1701a, 1701b) and gently pushed within said groove (1702) by means of external force or pressure in order to press fit said rib (1701) for a length (Y) formed by said slots (1701a, 1701b) in said groove (1702) of a length (Z). Whereas said rib (1702) can be penetrated within said groove (1702) for height (P) formed by said slots (1701a, 1701b) in the depth (Q) of said groove (1702) in order lock said rib (1701) within said groove (1702) to restrict all degrees of freedom and motions to form a rigid and robust configuration of said rib (1701) and said tile (1703) in order to perform the refining of the raw material input by means of Length (X) of said refiner disc (200, 400, 2000, 2100, 2200). In one of the embodiments said configuration rib (1701) inserted in said groove (1702) for said height (P) protects said rib (1702) from sliding vertically or horizontally. In another embodiment said the Length (Z) of said groove (1702) opening or said groove (1702) opening can be equal to or slightly larger than the length (Y) of said rib (1701) in a manner to achieve the press fit or tight fit of said rib (1701) and said groove (1702). However, said height (P) and said depth (Q) can be equal in dimension or the depth (Q) can be larger than said height (P) of said slot (1701a, 1701b). Whereas said groove (1702) can be drilled through said tile (1703) in case of said refiner disc (200, 400, 2000, 2100, 2200) in a manner said configuration of said rib (1701) with said tile (1703) facilitate smooth and streamline surface opposite to configuration of said rib (1702) with said tile (1703) and/or opposite protrusion of said length (X) from said groove (1702) of said tile (1703) in order to configure said base plate (300) evenly with said of said configuration of said tile (1703) and can be sufficiently deep to accommodate said height (P) said rib (1702) in case of said refiner disc (100).
In an embodiment, figure 18 illustrates about a rib (1801) with a locator (1802) articulated in said rib (1801) in a manner to allow the expandable flow restrictor shown in Figure no. 19 (i) to configure within said locator (1802) of said rib (1801). Wherein said locator (1802) can have different shapes, such as semi-circular, half-rectangular, or half-square, etc. Said locator (1802) configured to the rib (1801) and matches the tile's surface. Said locator (1802) allows said flow restrictor to be configured by top configuration without inserting from the bottom of said tiles (403, 503, 603). Said top configuration of said locator (1802) facilitates plurality of advantages which includes but not limits to easy replacement of said flow restrictor without removal of said tiles (403, 503, 603), easy and fast to assemble and/or disassemble, etc.
In an embodiment, figure 19 illustrates the various configurations of flow restrictors (1900). The flow restrictor (1900) is inserted into said exit groove (101, 201, 402, 504, 604, 704, 1001a to 1001g) made on said tile or surface (103, 203, 403. 503, 603) in order to confine in the space between said rib (104, 204, 404) configure with said grooves (102, 202, 405, 505, 605, 705) in order to allow measured flow of inputted material. Whereas said flow restrictor (1100) serves a dual purpose: it helps to lock with the tiles (203, 203, 403, 503, 603) to strengthen the configuration of said tiles (203, 203, 403, 503, 603) and/or with said rib (104, 204, 404) and also plays a role in controlling the flow of material between said ribs (104, 204, 404) to enhance the refining quality, thereby increasing the retention time of the material and improving the refining quality. Particularly, said flow restrictor (1100) is inserted from the bottom of the tile (203, 203, 403. 503, 603) and extends upwards to the top surface, where it locks the tiles (203, 203, 403. 503, 603) in place. This method not only secures the tiles (203, 203, 403. 503, 603) but also enhances the refining process by controlling the flow of pulp through the refiner disc (200, 400, 2000, 2100, 2200).
Figure 19a (a) shows a flow restrictor (1900a) of cross-sectional shape which includes but is not limited to circular, square, rectangular, pentagonal, hexagonal, octagonal, etc. Further, said flow restrictor (1900a) inserted in said exit groove (101, 201, 402, 504, 604, 704, 1001a to 1001g) from the top or bottom of the tile (203, 403, 503, 603), extending upwards to the top surface between said rib (104, 204, 404) configure with said grooves (202, 405, 505, 605, 705). Further, said flow restrictor (1900a) comprises a uniform diameter across the length and can be configured from top or bottom f top or bottom of the tile (203, 403, 503, 603). In one of the preferred embodiments, said flow restrictor (1900a) can be circular in cross-section and cylindrical in shape viewed from the side. This design allows the flow restrictor (1900a) to fit snugly into the tile ( 203, 403, 503, 603), in order to create a secure and watertight seal.
Figure 19a (b, c): illustrates the full type of a flow restrictor (1900b and 1900c) that can be configure from the bottom of said tiles (203, 403, 503, 603) in order to form configuration with said tile ( 203, 403, 503, 603) to offer complete local obstruction to material flow in the space between said rib (104, 204, 404). Wherein said flow restrictor (1900b and 1900c) includes local or peripheral notch (1900ba, 1900ca) in order to lock said flow restrictor (1900b and 1900c) with said tile ( 203, 403, 503, 603) at the bottom or side opposite to protruding out of said surface of said tile ( 203, 403, 503, 603) in order to form robust and rigid configuration of said flow restrictor (1900b and 1900c) with said refiner disc (200, 300, 400, 2000, 2100, 2000). However, the shape of said flow restrictor notch (1900ba and 1900ca) can be of type which includes but not limited to semi-circular, square, rectangular, oval, ellipsoidal, etc., whereas the cross-sectional and overall shape of said flow restrictor (1900b and 1900c) in accordance with said flow restrictor (1900a).
Figure 19a (d, e, f): illustrates the full type of a flow restrictor (1900d, 1900e, and 1900f) that can be configured from the bottom of said tiles (203, 403, 503, 603) in order to form configuration with said tile ( 203, 403, 503, 603) in order to offer local complete obstruction to flow in the configuration space between said rib (104, 204, 404). Wherein said flow restrictor (1900d, 1900e and 1900f) includes bottom extension (1900da, 1900ea and 1900fa) instead of said local or peripheral notch (1900ba, 1900ca) in order to lock said flow restrictor (1900d, 1900e and 1900f) below said tile (203, 403, 503, 603, 703) with confining said bottom extension between said tile (203, 403, 503, 603) and said base plate (300) in order to form robust and rigid configuration of said flow restrictor (1900d, 1900e and 1900f) with said refiner disc (200, 300, 400, 2000, 2100, 2200). However, the shape of said bottom extension (1900da, 1900ea, and 1900fa) can be of type which includes but not limits to semi-circular, square, rectangular, oval, ellipsoidal, etc, extending out of diameter cross-sectional of the top side (1900db, 1900eb and 1900fb) of said flow restrictor (1900d, 1900e and 1900f) whereas the cross-sectional of top side (1900db, 1900eb and 1900fb) said flow restrictor (1900d, 1900e and 1900f) in accordance with said flow restrictor (1900a).
Figure 19a (g, h, I, j ) and 19b : illustrates a partial flow restrictor (1900g, 1900h, 1900i, 1900j and 1900k) that can be configured from the bottom of said tiles (203, 403, 503, 603) in order to form configuration with said tile ( 203, 403, 503, 603). Wherein said flow restrictor (1900g, 1900h, 1900i, 1900j and 1900k) includes escape (1900ga, 1900ha, 1900ia, 1900ja and 1900ka) at any of side of said flow restrictor (1900g, 1900h, 1900i, 1900j and 1900k) periphery in order to allow the partial amount of material flow from said flow restrictor (1900g, 1900h, 1900i, 1900j and 1900k) in the space between said rib (104, 204, 404) to avoid chocking of the material between the pair of said refiner disc (100, 200, 400, 2000, 2100, 2200) during the operation or refining action of said refiner. Wherein said flow restrictor (1900g, 1900h, 1900i, 1900j and 1900k) can be configured with said title (203, 403, 503, 603, 703) in accordance with any of previous flow restrictor (1900a to 1900f) with said refiner disc (200, 300, 400, 2000, 2100, 2200). However, said escape (1900ga, 1900ha, 1900ia, 1900ja and 1900ka) can be of type which included but not limits to quarter, half, three quarter, partial, etc, designed in accordance with the application requirement. In one of the embodiment said escape (1900ga) can be quarter type and provided on any side of said flow restrictor (1900g) in order to allow small amount of flow from configuration of said flow restrictor (1900g), said escape (1900ha) can be half type and provided on both side of said flow restrictor (1900h) and wherein said flow restrictor (1900h) can be triangular in shape in order to allow half of the flow from both sides of configuration of said flow restrictor (1900h), said escape (1900ia) can be again half type which provided between the limbs of said flow restrictor (1900i) in order to allow half amount of flow to pass within the configuration of said flow restrictor (1900i), said escape (1900ja) can be quarter type and at least any one side of said flow restrictor (1900g) can be of shape which include but not limits to L or J configured in order to allow measured flow from one side of said flow restrictor (1900j) configuration and said escape (1900ka) can be three quarter or half type and provided on both top side of said flow restrictor (1900k), wherein said flow restrictor (1900k) can be of shape which include but not limits to trapezoidal, octagonal, hexagonal, pentagonal, etc. in order to allow the flow to pass from both sides over the configuration of said flow restrictor (1900k). However, said partial said flow restrictor (1900g, 1900h, 1900i, 1900j and 1900k) protect said refiner disc (100, 200, 400, 2000, 2100, 2200) from choaking, heating and ensure continuous operation wherein the possibility of choking of said refiner is higher and can be preferred in case of high consistency refining operation but can be implemented in case of low refining operation as well with more material flow required and good refining quality in less retention time intended.
In an embodiment, a single spiral (2005) configuration for a refiner disc (2000) with single exit groove (2001, 2001a) between said rib (2004) or said groove (2002 or 2000a) shown in figure 20a to 20c, wherein said refiner disc (2000) can be divided into the even number of sectors which include but not limits to 2, 4, 6, 8, 10, 12, 16 etc. In one of exemplary embodiment said refiner disc (2000) divided into 12 sectors (2000a- to 200l) and the exit grooves (2001) manufactured across said sectors (2000a- to 2006) on a tile (2003) in a manner to follow at least one spiral (2005) path of the projection in order to offer the spiral type of refining effect to the inputted raw material. Wherein said exit grooves (2001) formed between the grooves (2002) in order to offer the channel to configure the flow restrictor (2008, 2008a) between the ribs (2004) configured in said groove (2002). Further, said exit grooves (2001) were manufactured in a manner to form a first spiral (2005a) from said sector (2000f) to said sector (2000a) gradually increasing from an input end (2006) towards an output end (2007) of said refiner disc (2000), whereas a second spiral (2005b) starts immediately from next sector (200l) to said sector (2000g) following similar pattern as of said first spiral (2005a). Furthermore, during the making of said spiral (2005) type of configuration of exit grooves (2001) some of said grooves (2002) which do not cross said spiral (2005) path of said exit grooves (2001) can be processed with the formation of a local exit groove (2001a) in order to allow configuration of said flow restrictor (2008) between each of said rib (2004) configure in said groove (2002) and achieving the single setup machining and said groove (2001, 2002) manufacturing feature for said spiral (2005) type of configuration for said refiner disc (2000). In one of the embodiments said local exit grooves (2001a) can be manufactured along said output end (2007) for the grooves (2002) which do not cross said spiral (2005) path of said exit grooves (2001). In another embodiment said local exit grooves (2001a) can be made to join shorter grooves (2002a) which do not cross said spiral (2005) path of said exit groove and/or are short in length to not extend completely from said input end (2006) to said output end (2007). However, said local exit grooves (2001a) allow said grooves (2001, 2002) to be manufactured in a single setup machining manner and facilitate the configuration of a local flow restrictor (2008a) to prevent the flow of non-refined and/or partially refined material from said refiner disc (2000) as an output. In another embodiment, as shown in Figure 20b said spiral (2005) depicts the pulp refining effect focusing to the specific angles and variations, wherein said spiral (2005) with an angle range of 160° to 175°, which is optimized for creating a smooth, gradual increase in the refining load as the pulp gradually moves outward during processing. In one of the embodiments said spiral (2005) starts at 0° from said input (2006) and gradually increases till 180° to reach the extreme outlet of said output end (2007) of said disc (2000) in order to allow inlet of raw material enter at 0° and direct into said spiral (2005) in order to convert said inlet raw material to a processed pulp with intended effect to expel as an accepted output at 180° from said output end (2007). In one of the embodiments, it is apparent to the person skilled in the art that if said first spiral (2005a) starts from 0° and ends at 180°, then said second spiral (2005b) can start from 180° and ends at 0° or 360° in order to cover complete 360° periphery of said refiner disc (2000) by said spiral (2005). Moreover, 360° of said spiral configuration (2000) ensures that the pulp is processed evenly without sudden increases in pressure or load, which could otherwise cause disruptions in the refining process. The figure also illustrates different spiral angles that can be used to tailor the refining process for specific pulp characteristics, ensuring that said disc (2000) performs optimally for a wide range of refining tasks. In another embodiment, said flow restrictor (2008) configured in said exit groove (2001) and said local flow restrictor (2008a) configured in said local exit groove (2001a) in the manner shown in figure no. 20c. Whereas in one of the preferred embodiment either said flow restrictor (2008) can be configured in said exit groove (2001) or said local flow restrictor (2008a) can be configured in said local exit groove (2001a) in a manner to ensure appearance only one of said flow restrictor (2008) or said flow restrictor (2008a). Similarly, in another preferred embodiment either said exit groove (2001) can be formed between said two grooves (2002) or said local exit groove (2001a) can be manufactured between said two grooves (2002) or said shorter grooves (2002a) in a manner to ensure appearance only one of said exit groove (2001) or said local exit groove (2001a) between pair of said grooves (2002) or said shorter grooves (2002a) or said rib (2004) in order to allow manufacturing of said refiner disc (2000) by means of said single setup machining method and formation of the configuration of said spiral (2005) in order to increase the refining retention time gradually to increase the refining load gradually from said input end (2006) towards said output end (2007) without generating the excessive local load, clogging of the material and facilitates smooth streamline uniform processing of the raw material along said spiral path (2005a, 2005b) to provide the refined output at the output end (2007) with each said sector (2000a to 2000l) contributing equally to the overall refining process. In one of the embodiments, said single spiral pattern (2005) of the trajectory of said flow restrictors (2008) can be articulated clockwise or anticlockwise direction in accordance with the rotating direction of said refiner disc (2000) in order to reduce the refining load.
In an embodiment, a dual spiral (2105) configuration for a refiner disc (2100) with a single exit groove (2101, 2101a) between said rib (2104) configured with said groove (2102 or 2100a) shown in figure 21a to 21c, wherein said refiner disc (2100) divided into the plurality of sectors (2100a- to 2100l) and the exit grooves (2101) manufactured across said sectors (2100a- to 2100l) on a tile (2103) in a manner only one of said exit groove (2101) will appear within pair of said rib (2104) configured with said groove (2102 or 2100a) and follow at least any one of spiral (2105a, 2105b, 2105c, 2105d) path of the projection in order to offer the dual spiral (2105) type of refining effect to the inputted raw material. Wherein, said exit grooves (2101) formed between said rib (2104) configured with said groove (2102 or 2100a) in order to offer the channel to configure the flow restrictor (2108, 2108a) between said ribs (2104) configured in said grooves (2102). Further, said exit grooves (2101) were manufactured in a manner to commence said first spiral (2105a) from said sector (2100f) to said sector (2100a) gradually increasing from an input end (2106) towards an output end (2107) of said refiner disc (2100), whereas a second spiral (2105b) starts immediately from next sector (2101) to said sector (2100g) following similar pattern as of said first spiral (2105a). Whereas, said third spiral (2105c) and said fourth spiral (2105d) start from the middle and / or the halfway mark of said first spiral (2105a) and said second spiral (2105b) respectively to include more number of said grooves (2102) within said spiral (2105) pattern of said exit groove (2101) formation to reduce the number or requirement of a local exit groove (2101a) which facilitates more balanced refining with streamlined material processing without generation of local excessive blockage or loading to reduce the clogging, power consumption with prolonged life of said refiner disc (2100). Furthermore, in one of the exemplary embodiments said spiral (2105c) pattern of exit grooves (2101) commences from said sector (2100c) to said sector (2000j) in order to start at the middle of said spiral (2105a) and ends at the mid of said spiral (2105b), similarly said spiral (2105d) pattern of exit grooves (2101) commences from said sector (2100i) to said sector (2000d) in order to start at the middle of said spiral (2105b) and ends at the mid of said spiral (2105a) in one above another manner without crossing any of said spiral (2105a, 2105b) in order to maintain the material retention equally across the periphery of said refiner disc (2100) to nullify the end or start effect of said spiral (2105) as well as said dual spiral (2105) configuration reduces the number of said local exit groove (2101a) in order to eliminate or reduce the local concentrated processing material retention to enhance the pulp refining efficacy. However, if any local exit groove (2101a) exists or few of said local exit grooves (2101a) during the making of said dual spiral (2105) type of configuration of exit grooves (2101), that numbers of said grooves (2102) do not cross during said dual spiral (2105) path of said exit grooves (2101) can be processed with the formation of a local exit groove (2101a) in order to allow the configuration of said flow restrictor (2108) between each of said rib (2104) configure in said groove (2102) and achieving the single setup machining and said groove (2101, 2102) manufacturing feature for said dual spiral (2105) type of configuration for said refiner disc (2100). In one of the embodiments if any of said local exit grooves (2101a) required to manufacture can be manufactured above the lower spiral (2105) that exists across any of said sectors (2100a-210l) for the grooves (2102) which do not cross said dual spiral (2105) path of said exit grooves (2101). In another embodiment said local exit grooves (2101a) can be made to join shorter grooves (2102a) which do not cross said spiral (2105) path of said exit groove and/or are short in length to not extend completely from said input end (2106) to said output end (2107). However, said local exit grooves(2101a) allow said grooves (2101,2102) to be manufactured in a single setup machining manner and facilitate the configuration of a local flow restrictor (2108a) to prevent the flow of non-refined or partially refined material from said refiner disc (2100) as an output. Moreover, said dual spiral (2105) pattern of exit grooves (2101) can be achieved by means of said single machining setup method by designing said exit grooves (2101) in an alteration or zigzag manner (2109) as shown in figure no. 21b. Wherein said exit grooves (2101) can be formed in a manner only one of said groove (2101) exists in one pair of said groove(2102) or pair of said rib (2104) either near to output end (2107) top side or near to the bottom side (2106) of said sectors (2100a to 210l) in a manner if one of said exit groove (2101) formed near to said output end (2107) within the pair of said groove(2102) or pair of said rib (2104) the very next exit groove (2101) will be formed near to said input end (2106) in a manner if first exit groove (2101) crosses any of said spiral (2105a, 2105b) then very next and previous exist groove (2101) will cross any of said spiral (2105c, 2105d) and vice a versa in order to articulate said exit groove (2101) in alternate or zigzag pattern (2109) to cross all the four of said spiral (2105a, 2105b, 2105c, 2105d) alternatively in order to form the dual spiral (2105) configuration for said refiner disc (2100) using said single setup machining method to propel the tool continuously for formation of one groove (2102) to another groove (2102) continuously using said single exit groove (2101) between pair grooves (2102).
In one of the embodiments said spiral (2105a) starts at 0° from said input (2106) and gradually increases to 180° in order to achieve the extreme outlet of said output end (2107) of said disc (2100) in order to allow inlet of raw material enter at 0° and direct into said spiral (2105) to convert the inlet raw material to a processed pulp with intended effect to expel as an accepted output at 180° from said output end (2107), and said spiral (2105c) starts at 90° from said input (2106) and gradually increases till 270° to reach the extreme outlet of said output end (2107) of said disc (2100) to allow inlet of raw material enter at 90° and direct into said spiral (2105c) in order to convert said inlet raw material to a processed pulp with intended effect to expel as an accepted output at 270° from said output end (2107). In other embodiments, it is apparent to a person skilled in the art that if said spiral (2105a) starts from 0° and ends at 180° and said spiral (2105c) starts from 90° and ends at 270° then said spiral (2105b) can start from 180° and ends at 0° or 360° and said spiral (2105d) starts from 270° and ends at 90° vice versa in order to cover complete 360° periphery of said refiner disc (2100) by said dual spiral (2105). However, said 360° of said dual spiral configuration (2105) ensures that the pulp is processed effectively without sudden increases in pressure or load, which could otherwise cause disruptions in the refining process.
In another embodiment, as shown in figure 21c and 21d; said dual spiral (2105) can be formulated with the configuration said flow restrictor (2108) and with or without configuration of said local flow restrictor (2108a). Wherein said flow restrictor (2108) is configured in said exit groove (2101) and said local flow restrictor (2108a) is configured in said local exit groove (2101a) in the manner shown in figure no. 21c and 21d in order to ensure the appearance of only one of said flow restrictors (2108) or said flow restrictor (2108a) in one pair of said groove (2102) in any of said spiral (2105a, 2105b, 2105c, 2105d) as shown in figure no. 21d. Whereas in one of the preferred embodiments only said flow restrictor (2108) can be configured in said exit groove (2101) without said local flow restrictor (2108a) by skipping said local exit groove (2102a) in order to allow material output from said local flow restrictor (2108a) grooves (2102a) as shown in figure no. 21c. Further said flow restrictor (2108a) can be configured in said local exit groove (2101a) in a manner to ensure the appearance of only one of said flow restrictors (2108) or said flow restrictor (2108a) including the configuration of said local flow restrictor (2108a) in said local exit groove (2102a) configured across any of said dual spiral (2105a, 2105b, 2105c, 2105d) as shown in figure no. 21d. Moreover, in another embodiment said configuration of only one flow restrictor (2108 and 2108a) offers wide pulp refining opportunities to process both low-consistency and high-consistency pulp refining in accordance with the material output requirement or application at a lower cost of said refiner disc (2100) and higher refining retention time and gradually increasing refining load from said input end (2106) towards said output end (2107) without generating the excessive local load, clogging of the material and facilitates smooth streamline uniform processing of the raw material along said dual spiral path (2105a, 2105b, 2105c, 2105d) to provide the refined output at the output end (2107) with each said sectors (2100a to 2100l) contributing equally to the overall refining process. In one of the embodiments, said dual spiral pattern (2105) of trajectory of said flow restrictors (2108, 2108a) can be articulated clockwise or anticlockwise direction in accordance with the rotating direction of said refiner disc (2100) in order to reduce the refining load.
In an embodiment, a curved pattern (2205) configuration for a refiner disc (2200) with single exit groove (2201) between said rib (2204) configured with said groove (2202) as shown in figure 22a to 22b, wherein said refiner disc (2200) divided into the plurality of sectors (2200a) which include a curved patterned (2205) of said exit grooves (2202) manufactured across each said sectors (2100a) on a tile (2203) in a manner only one of said exit groove (2201) will appear within a valley (2210) formed by said pair of said rib (2204) configured with said groove (2202) and follow curved pattern (2205) path of the projection which start and end in same sector (2200a) in order to offer curved guided type of refining effect to the inputted raw material for each sector (2200a). Wherein, said exit grooves (2201) formed in said valley (2210) between said rib (2204) configured with said groove (2202) offer the channel to configure the flow restrictor (2208) between the ribs (2204) configured in said grooves (2202). Further, said exit grooves (2201) formed in said curved pattern (2205) commenced at a specified length (2210) from said input end (2206) in order to allow a sufficient amount of input material required to be processed by means of said refiner disc (2200) and the percentage of said input material gradually increases in accordance with the increase in the trajectory of said curved pattern (2205) of said exit grooves (2201) to an output end (2207) of said sector (2202a). In one of the embodiments the commencement length (2211) of commencement of said curved pattern (2205) can be designed in a manner to complete said curved pattern (2202) trajectory within said sector (2200a) in order to perform homogeneous balanced pulp refining within the sector (2200a) only. In one of the preferred embodiments the commencement length (2211) of said exit grooves (2202) can be in the range of 10% larger than said sector length (22012) from said input end (2206) and smaller than 50% of said sector length (2212) from said input end (2206). Furthermore, a same or similar type of said curved pattern (2205) of said exit grooves (2201) can be followed for all of the other configuring sectors (2200a) that are required to be configured to formulate said refiner disc (2200). Wherein said configuration curved pattern (2205) of said exit grooves (2201) for said refiner disc (2200) results in loading all sectors equally to facilitate the balanced processing and same or similar type of said curved pattern (2205) geometry facilitates the same or similar type of processing effect to the input material that comes across each of said sector (2200a) to provide the output same or similar quality from each of said sector (2200a) to enhance the efficacy of said refining process and said refined pulp and said curved pattern (2205) ending within each of said sector (2200a) expels the processed output from each of said sector (2200a) to increase the output of said refiner disc (2200). Moreover, as shown in figure no. 22b said flow restrictor (2208) can be configured in said curved pattern (2205) of said exit grooves (2201) and said ribs (2204) configured in said grooves (2202) in order to block said valley (2210) formed between said pair of ribs (2204) by means of said flow restrictor (2208). In one of the embodiments said flow restrictor (2208) can be of shape as of curved pattern (2205) of said exit groove (2202) geometry to form said curved pattern (2205) trajectory of said flow restrictor (2208). Whereas said curved pattern (2205) of the trajectory of said flow restrictors (2208) can be articulated clockwise or anticlockwise direction as per the rotating direction of said refiner disc (2200) to reduce the refining load. In a further embodiment it is apparent to a person skilled in the art that the direction of said grooves (2202) formed in said sector (2200a) can be the same or different for all sectors (2200a) configured across refiner disc (2200) to complete the configuration of said refiner disc (2200) and can be selected in accordance with the application requirement or type of pulp refining required, but said curved pattern (2205) of said flow restrictor (2208) can be same or similar across all sectors configured across said refiner disc (2200).
TECHNOLOGICAL ADVANCEMENTS:
The present disclosure described herein has several technical advantages, including, but not limited to, the single setup manufacturing method and the refiner disc produced therefrom, which:
• Manufacture said groove for said refiner disc including said tile for said refiner disc in a single machining setup.
• Performing said groove manufacturing operation without removing or uplifting the machining tool from said groove to manufacture all grooves required to manufacture across the tile in a single machine setup.
• Facilities the refiner disc with a single exit groove and to configure a flow restrictor with the refiner disc in order to maintain a continuous machining trajectory.
• Flexible design of said refiner disc tile to simultaneously accommodate said rib and flow restrictor in order to enhance the integrity.
• Provides robust configuration for the rib with the tile using an interference or tight fit.
• Facilitate the smooth and streamlined surface in the configuration of the tile and rib for a base plate.
• Possibility of the configuration of various varieties of said flow restrictor and exit groove configuration.
• Robust and rigid formulation of said refiner disc by locking of tiles and welding of said base plate.
• Enhance the refining pattern with homogeneous output with better balancing and reduce the refining load by single spiral, dual spiral type of exit groove, and said flow restrictor configuration pattern.
• Interchangeable segment configuration with increased output by means of the curved pattern configuration of the exit groove and said flow restrictor.
• Reduce the manufacturing time and cost for said tile and refiner disc.
• Increase the efficiency and efficacy of said refiner disc at a low cost and manufacturing time with greater precision.
The embodiment described herein, along with its various features and advantages, is explained with reference to non-limiting examples in the following descriptions. Descriptions of well-known components and processing techniques are omitted to avoid unnecessarily obscuring the embodiment; the examples provided are intended merely to illustrate ways in which the embodiments may be practiced and to further enable those skilled in the art to implement the disclosed embodiments. Accordingly, these examples should not be construed as limiting the scope of the embodiments.
It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not limitation. Those skilled in the art will recognize that the embodiments can be practiced with modifications within the spirit and scope of the described embodiments.
Throughout this specification, the term “comprise” and its variations, such as “comprises” or “comprising,” imply the inclusion of a stated element, integer, step, or group of elements, integers, or steps, but do not exclude any other elements, integers, or steps.
The expressions “at least” or “at least one” suggest the inclusion of one or more elements, ingredients, or quantities, as necessary to achieve one or more of the desired objectives or results in the disclosed embodiments.
Any discussion of documents, acts, materials, devices, articles, or similar items included in this specification is solely for the purpose of providing context for the disclosure and should not be interpreted as an admission that any or all of these matters are part of the prior art or were common general knowledge in the relevant field before the priority date of this application.
While considerable emphasis has been placed on the components and parts of the preferred embodiment, it should be appreciated that many embodiments can be developed, and numerous modifications can be made to the preferred embodiments without departing from the principles of the disclosure. These and other changes, as well as other embodiments of the disclosure, will be apparent to those skilled in the art from the information provided herein. Thus, it is to be distinctly understood that the foregoing descriptive material is illustrative of the disclosure and not a limitation.
Dated this 11th day of September 2024

Shailendra Omprakash Khojare,
IN/PA-4041
Applicants Patent Agent

,CLAIMS:CLAIMS
We claim;
1. A refiner disc (200, 400, 2000, 2100, 2200) comprising:
o a base plate (300);
o a plurality of ribs (204, 404, 1102, 1701, 1801, 2004, 2104, 2204); and
o a plurality of tiles (205, 503, 603, 703, 801, 901, 1103, 1303, 1503,1603, 1703, 2003, 2103, 2203);
o wherein said plurality of ribs (204, 404, 1102, 1701, 1801, 2004, 2104, 2204 ) configured with said tile (205, 503, 603, 703, 801, 901,1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) and said tile (205, 503, 603, 703, 801, 901, 1103, 1303, 1503, 1603, 1703, 2003, 2103, 2203) is configured with said base plate (300) to form said refiner disc (200, 400, 2000, 2100, 2200);
o wherein said tile (205, 503, 603, 703, 801, 901, 1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) comprises a plurality of grooves (202, 401, 505, 605, 705, 802, 902, 1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga, 1301, 1602, 1702, 2002, 2102) formed across the tiles (205, 503, 603, 703, 801, 901, 1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) surface, each said groove (202, 401, 505, 605, 705, 802, 902, 1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga, 1301, 1602, 1702, 2002, 2102) parallel to each other configured to accommodate said ribs (204, 404, 1102, 1701, 1801, 2004, 2104, 2204) and forms a narrow channel or valley (403, 1001ab, 1001bb, 1001cb, 1001db, 1001eb, 1001fb, 1001gb, 2210) on the tile (205, 503, 603, 703, 801, 901, 1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) surface between each said ribs (204, 404, 1102, 1701, 1801, 2004, 2104, 2204);
o wherein said plurality of grooves (202, 401, 505, 605, 705, 802, 902, 1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga, 1301, 1602, 1702, 2002, 2102) comprises at least an exit groove ( 201, 402, 504, 604, 704, 1001a—g, 1100, 1302, 1401, 1501, 1601, 2001, 2001a, 2101, 2101a, 2201), said exit groove ( 201, 402, 504, 604, 704, 1001a—g, 1100, 1302, 1401, 1501, 1601, 2001, 2001a, 2101, 2101a, 2201) accommodating ribs (205, 503, 603, 703, 801, 901, 1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) appears to form a bridge between two consecutive grooves (202, 401, 505, 605, 705, 802, 902, 1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga, 1301, 1602, 1702, 2002, 2102) in said narrow channel or valley (403, 1001ab, 1001bb, 1001cb, 1001db, 1001eb, 1001fb, 1001gb, 2210)wherein said plurality of grooves (202, 401, 505, 605, 705, 802, 902, 1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga, 1301, 1602, 1702, 2002, 2102) and said exit groove ( 201, 402, 504, 604, 704, 1001a—g, 1100, 1302, 1401, 1501, 1601, 2001, 2001a, 2101, 2101a, 2201) formed by means of a single setup of machining formation.
2. The refiner disc (200, 400, 2000, 2100, 2200) of claim 1, wherein said groove (202, 401, 505, 605, 705, 802, 902, 1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga, 1301, 1602, 1702, 2002, 2102) includes said exit groove (101,201,402, 504, 604, 704, 1001a—g, 1100, 1302, 1401, 1501, 1601, 2001, 2101-2, 2201- 2202,2105a-, 2101a, 21001) configured to allow secure insertion and locking of the rib (204, 404, 1102, 1701, 1801, 2004, 2104, 2204) and a flow restrictor (1101, 1900, 2008, 2108, 2208) with said tile (205, 503, 603, 703, 801, 901,1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) from one side of said tile (205, 503, 603, 703, 801, 901,1103, 1303, 1503,1603, 1703, 2003, 2103, 2203).
3. The refiner disc (200, 400, 2000, 2100, 2200) of claim 1, wherein the grooves (202, 401, 505, 605, 705, 802, 902, 1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga, 1301, 1602, 1702, 2002, 2102) are parallel and evenly spaced across the tile surface to ensure uniform distribution of ribs (104, 204, 404, 1102, 1301, 1701, 1801, 2004, 2104, 2204).
4. The refiner disc (200, 400, 2000, 2100, 2200) of claim 1, wherein the grooves (202, 401, 505, 605, 705, 802, 902, 1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga, 1301, 1602, 1702, 2002, 2102) are machined with precise dimensions to ensure a tight fit for the ribs (104, 204, 404, 1102, 1301, 1701, 1801, 2004, 2104, 2204), maintaining the structural integrity of the refiner disc (200, 400, 2000, 2100, 2200).
5. The refiner disc (200, 400, 2000, 2100, 2200) of claim 1, wherein the tiles (205, 503, 603, 703, 801, 901,1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) are locked together using a plug (501, 601, 701) and socket (502, 602, 702) type locking mechanism, wherein one tile (205, 503, 603, 703, 801, 901,1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) includes a protruding plug (501, 601, 701) and an adjacent tile (205, 503, 603, 703, 801, 901,1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) includes a corresponding socket (502, 602, 702) .
6. The refiner disc (200, 400, 2000, 2100, 2200) of claim 5, wherein said protruding plug (501, 601, 701) and socket (502, 602, 702) comprises the shape from the group consisting of pentagonal, hexagonal or trapezoidal or dovetail, rectangular, square or U-shaped, elliptical, semi-circular, curved or circular.
7. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein said flow restrictor (1101, 1900, 2008, 2108, 2208) inserted into the exit groove (201, 402, 504, 604, 704, 1001a—g, 1100, 1302, 1401, 1501, 1601, 2001, 2001a, 2101, 2101a, 2201) on the tile (205, 503, 603, 703, 801, 901,1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) in a manner to projects between adjacent ribs (204, 404, 1102, 1701, 1801, 2004, 2104, 2204).
8. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein said tiles (205, 503, 603, 703, 801, 901,1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) configured with said ribs (204, 404, 1102, 1701, 1801, 2004, 2104, 2204) and said flow restrictor (1101, 1900, 2008, 2108, 2208) secured to said base plate (300) by welding at specific points (301), creating a strong bond with minimal material stress.
9. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein said base plate (300) includes grooves or recesses to accommodate and hold the interlocked said tiles (205, 503, 603, 703, 801, 901,1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) in place.
10. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein the ribs (1801) include specific features, such as slots or notches, that allow secure insertion and stabilization of the lateral flow restrictor (1900i).
11. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein each said ribs (204, 404, 1102, 1701, 1801, 2004, 2104, 2204) has a height (P) and each said groove (202, 401, 505, 605, 705, 802, 902, 1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga, 1301, 1602, 1702, 2002, 2102) has depth (Q), which may be equal in dimension or the depth (Q) of said tiles (205, 503, 603, 703, 801, 901,1103, 1303, 1503,1603, 1703, 2003, 2103, 2203), or may be larger than said height (P) of said slot (1701a, 1701b) configure without extending below said tiles (205, 503, 603, 703, 801, 901,1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) along surface configuring with said base plate (300) in the opposite direction of said rib (204, 404, 1102, 1701, 1801, 2004, 2104, 2204) protrusion from said groove to form a length (X).
12. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein said exit grooves (201, 402, 504, 604, 704, 1001a—g, 1100, 1302, 1401, 1501, 1601, 2001, 2001a, 2101, 2101a, 2201) configured in advanced patterns which comprises but not limits to stepped, inclined, curved, single spiral, double spiral, forms to process the flow of material.
13. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein a first spiral (2005a) of said exit groove (2001) starts at 0° from said input (2006) and gradually increases till 180° to reach the extreme outlet of said output end (2007) and said second spiral (2005b) start from 180° and ends at 0° or 360° for said single spiral (2005) configuration.
14. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein said spiral (2005a) starts at 0° from said input (2006) and gradually increases till 180° to reach the extreme outlet of said output end (2007) and said second spiral (2005b) start from 180° and ends at 0° or 360° for said single spiral (2005) configuration in order to complete 360° periphery of said refiner disc (2000) by said single spiral (2005).
15. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein in case of said dual spiral (2105) configuration of said exit grooves (2101) a first spiral (2105a) starts at 0° to end at 180° gradually increasing from an input end (2106) towards an output end (2107) and a second spiral (2105b) starts immediately from 180° to end at 0° or 360° following a similar pattern as of said first spiral (2105a), whereas, a third spiral (2105c) starts 90° to end at 270° gradually increasing from an input end (2106) towards an output end (2107) and a fourth spiral (2105d) starts from 270° to ends at 90° in a manner said third spiral (2105c) and said fourth spiral (2105d) start from the middle and/or the halfway mark of said first spiral (2105a) and said second spiral (2105b) in order to complete 360° periphery of said refiner disc (2100) by said dual spiral (2105) configuration.
16. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein said groove (202, 401, 505, 605, 705, 802, 902, 1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga, 1301, 1602, 1702, 2002, 2102) does not cross with said spiral (2005, 2105) can be connected with a local exit groove (2001a, 21001a).
17. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein said local exit grooves (2001a, 21001a) manufactured along said output end (2007, 2107) for the grooves (202, 401, 505, 605, 705, 802, 902, 1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga, 1301, 1602, 1702, 2002, 2102) which do not cross said spiral (2005, 2105).
18. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein said flow restrictor (1101, 1900, 2008, 2108, 2208) may or may not be configured in said local exit grooves (2001a, 21001a).
19. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein said flow restrictor (1101, 1900, 2008, 2108, 2208) configured in said local exit groove (2001a, 2101a) in a manner to ensure the appearance of only one of said flow restrictors (1101, 1900, 2008, 2108, 2208) or said local flow restrictor (2008a, 2108a) between said groove (202, 401, 505, 605, 705, 802, 902, 1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga, 1301, 1602, 1702, 2002, 2102) or said rib (204, 404, 1102, 1701, 1801, 2004, 2104, 2204) in said exit grooves (201, 402, 504, 604, 704, 1001a—g, 1100, 1302, 1401, 1501, 1601, 2001, 2101, 2201) or said local exit grooves (2001a, 2101a) across any of said single spiral (2005a, 2005b) or said dual spiral (2105a, 2105b, 2105c, 2105d).
20. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein said exit grooves (2201) formed in a curved pattern (2205) commenced at a specified length (2210) from an input end (2206) and gradually increases in accordance with the increase in the trajectory of said curved pattern (2205) of said exit grooves (2201) to an output end (2207) of same sector (2202a) in order to complete said curved pattern (2205) within same sector (2202a) .
21. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein the flow restrictor (1101, 1900, 2008, 2108, 2208) comprises
a full type of a flow restrictor (1900a to 1900f) having shape from the group consisting of cylindrical, circular, square, rectangular, pentagonal, hexagonal, octagonal, concave and convex cross-section, and/or
a partial type of a flow restrictor (1900g to 1900j) with quarter, half, three quarter, partial escape (1900ga, 1900ha, 1900ia, 1900ja, 1900ka) with partially cut, triangular, pentagonal, trapezoidal, “L”, “J”, “U” or opening of inverted “U” or “U” shaped cross-section in order to regulate the flow of material between the ribs (204, 404, 1102, 1301, 1701, 1801, 2004, 2104, 2204).
22. The refiner disc (100, 200, 400, 2000, 2100, 2200) of claim 1, wherein the flow restrictor (1101, 1900, 2008, 2108, 2208) locked with said tile (205, 503, 603, 703, 801, 901,1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) by means of a notch (1900ba, 1900ca) or a bottom extension (1900da, 1900ea and 1900fa).
23. The refiner disc (200, 400, 2000, 2100, 2200) of claim 1, wherein the exit grooves (504, 604, 704, 1501) can be formed within said sectors (506a, 506b, 606a, 606b, 706a, 706b, 706c, 706d, 706e, 706f) serve as connectors between said parallel grooves (202, 401, 505, 605, 705, 802, 902, 1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga, 1301, 1602, 1702, 2002, 2102) allowing for flexibility and movement of said machining tool.
24. The refiner disc (200, 400, 2000, 2100, 2200) of claim 1, wherein exit grooves (201, 402, 504, 604, 704, 1001a—g, 1100, 1302, 1401, 1501, 1601, 2001, 2001a, 2101, 2101a, 2201) may be of the type which comprises but not limit to parallel or straight (1001b), slanted or inclined, curved, convex, concave, notch, curved inward, curved outward, wave-like, curving form in the middle, angular diagonally.
25. The refiner disc (200, 400, 2000, 2100, 2200) of claim 1, wherein, said exit grooves (201, 402, 504, 604, 704, 1001a—g, 1100, 1302, 1401, 1501, 1601, 2001, 2001a, 2101, 2101a, 2201) are forming a staggered, zigzag pattern by being offset from each other forming V shaped configuration with or without a central straight groove (1302) cross said center (1305), wherein, said exit grooves (1302) on one side of said parallel groove (1301) are not directly opposite the exit grooves (1302) on the other side of the adjacent parallel groove (1301).
26. A method for manufacturing a refiner disc ( 200, 400, 2000, 2100, 2200), comprising:
a) Providing a base plate (300) ;
b) Forming plurality of ribs (104, 204, 404, 1102, 1301, 1701, 1801, 2004, 2104, 2204);
c) Machining plurality of tiles (205, 503, 603, 703, 801, 901,1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) to create a plurality of grooves (202, 401, 505, 605, 705, 802, 902, 1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga, 1301, 1602, 1702, 2002, 2102) across the tile (205, 503, 603, 703, 801, 901,1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) surfaces, wherein each groove (202, 401, 505, 605, 705, 802, 902, 1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga, 1301, 1602, 1702, 2002, 2102) parallel to each other and is configured to accommodate said ribs (104, 204, 404, 1102, 1301, 1701, 1801, 2004, 2104, 2204);
d) Configuring said plurality of grooves (202, 401, 505, 605, 705, 802, 902, 1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga, 1301, 1602, 1702, 2002, 2102) to include at least one exit groove (201, 402, 504, 604, 704, 1001a—g, 1100, 1302, 1401, 1501, 1601, 2001, 2001a, 2101, 2101a, 2201), said exit groove (201, 402, 504, 604, 704, 1001a—g, 1100, 1302, 1401, 1501, 1601, 2001, 2001a, 2101, 2101a, 2201) forming a bridge between two consecutive grooves (202, 401, 505, 605, 705, 802, 902, 1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga, 1301, 1602, 1702, 2002, 2102) in said narrow channel or valley(403, 1001ab, 1001bb, 1001cb, 1001db, 1001eb, 1001fb, 1001gb, 2210);
e) wherein said plurality of grooves (202, 401, 505, 605, 705, 802, 902, 1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga, 1301, 1602, 1702, 2002, 2102) and said exit grooves (201, 402, 504, 604, 704, 1001a—g, 1100, 1302, 1401, 1501, 1601, 2001, 2001a, 2101, 2101a, 2201) manufactured by means of a single setup of machining method,
f) Configuring said plurality of ribs (104, 204, 404, 1102, 1301, 1701, 1801, 2004, 2104, 2204) with single tile (205, 503, 603, 703, 801, 901,1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) and configuration of said plurality of said tiles (205, 503, 603, 703, 801, 901,1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) with said plurality of ribs (104, 204, 404, 1102, 1301, 1701, 1801, 2004, 2104, 2204) configure with each other in order to formulate a sector (207, 506a, 606b, 706a to 706f, 2000a to 2000l, 2100a to 2100l, 2200a to 2200l) or a segment (208),
g) Configuring said sector (207, 506a, 606b, 706a to 706f, 2000a to 2000l, 2100a to 2100l, 2200a to 2200l) or a segment (208) with said base plate (300), such that said ribs (204, 404, 1102, 1701, 1801, 2004, 2104, 2204) are aligned with said tiles (205, 503, 603, 703, 801, 901,1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) to form the refiner disc (200, 400, 2000, 2100, 2200).
27. The method of claim 26, wherein the step of manufacturing comprises said machining tool commences the drilling operation of grooves (202, 401, 505, 605, 705, 802, 902, 1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga, 1301, 1602, 1702, 2002, 2102) and exit grooves (201, 402, 504, 604, 704, 1001a—g, 1100, 1302, 1401, 1501, 1601, 2001, 2001a, 2101, 2101a, 2201) from an entry groove (505b, 605b, 705b) positioned with respect to any of the edge (507, 607, 707) of said tile (205, 503, 603, 703, 801, 901,1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) or a sector (207, 506a, 606b, 706a to 706f, 2000a to 2000l, 2100a to 2100l, 2200a to 2200l) or a segment (208).
28. The method of claim 26, wherein step of manufacturing comprises
said machining tool breaks said edge (507, 607, 707) in order to manufacture the first groove called said entry groove (505b, 605b, 705b) of edge (507, 607, 707) and continue operation without lifting or rising said machining tool till the formation of all of said grooves (202, 401, 505, 605, 705, 802, 902, 1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga, 1301, 1602, 1702, 2002, 2102) and exit grooves (201, 402, 504, 604, 704, 1001a—g, 1100, 1302, 1401, 1501, 1601, 2001, 2001a, 2101, 2101a, 2201) or an end groove (505a, 605a, 705a) manufactured on the opposite edge of said edge (507, 607, 707) with said entry groove (505b, 605b, 705b) in order to perform said machining operation in single setup.
29. The method of claim 26, wherein said end groove (505a, 606a, 706a) open into corresponding said groups or sectors (506a, 506b, 606a, 606b, 706a, 706b, 706c, 706d, 706e 706f) or configured at the exit of said tile (205, 503, 603, 703, 801, 901,1103, 1303, 1503,1603, 1703, 2003, 2103, 2203) or a sector (207, 506a, 606b, 706a to 706f, 2000a to 2000l, 2100a to 2100l, 2200a to 2200l) or a segment (208).
30. The method of claim 26, wherein the exit grooves (504, 604, 704, 1501) formed within said sectors (506a, 506b, 606a, 606b, 706a, 706b, 706c, 706d, 706e, 706f) to serve as connectors between said parallel grooves (202, 401, 505, 605, 705, 802, 902, 1001aa, 1001ba, 1001ca, 1001da, 1001ea, 1001fa, 1001ga, 1301, 1602, 1702, 2002, 2102) allowing for flexibility and movement of said machining tool.

Dated this 11th day of September 2024 Shailendra Omprakash Khojare,
IN/PA-4041
Applicants Patent Agent