Dual Rotor-Stator Pulper Layout to Reduce Plugging

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Solution Overview

Problem

Conventional pulpers face issues with plugging due to large material pieces, leading to reduced processing efficiency and increased operating costs, particularly in the initial breakdown and subsequent deflaking processes.

Innovation Solution

A defibering and deflaking pulper with dual rotor-stator pairs creates impeller-produced vortical circulation for efficient breakdown of fiber-based materials, combining defibering and deflaking stages to minimize plugging and enhance productivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single-stage pulper is used for initial breakdown, then the structure is simple, but large material pieces cause plugging and reduced productivity

Engineering Contradiction:

Improvepulper structureVSAvoidmaterial processing throughput

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The pulper is divided into two functional stages: a defibering rotor-stator pair for initial breakdown and a deflaking rotor-stator pair for secondary processing. This segmentation allows each stage to specialize in specific size reduction tasks, preventing plugging while maintaining manageable structural complexity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The deflaking rotor-stator pair is nested within the pulper chamber downstream of the defibering stage. The deflaking rotor is positioned between the defibering rotor-stator interface and the chamber wall, creating a compact nested arrangement where the second processing stage is integrated within the overall pulper structure

Inventive Principle:

Principle #7Nested doll (Nesting)

2Productivity

If rotor-stator interface is used for material breakdown, then cutting efficiency is improved, but plugging occurs due to large pieces

Engineering Contradiction:

Improvematerial breakdown efficiencyVSAvoidoperational continuity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The material breakdown process is segmented into two sequential rotor-stator interfaces: the first for defibering and the second for deflaking. This segmentation ensures that material is progressively reduced in size, preventing large pieces from causing plugging and maintaining operational continuity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The defibering rotor-stator pair performs preliminary size reduction on incoming material before it reaches the deflaking stage. This preliminary action breaks down large material pieces into smaller fragments, preventing them from causing plugging in downstream components and ensuring reliable continuous operation

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The dual-stage pulper effectively reduces plugging and enhances productivity by breaking down materials into smaller pieces, optimizing throughput and reducing operating costs.

Implementation Method 1

the rotor creates an impeller-produced vortical circulation that pulls the material and water through the rotor-stator interface

Methodology Applied

Scientific EffectVortical circulation: Vortex Ring

Implementation Method 2

The material is broken down primarily in the relatively small zone immediately adjacent to the spinning rotor where there is sufficient turbulence and shear forces

Methodology Applied

Scientific EffectShear forces: Shear Stress

Implementation Method 3

there is sufficient turbulence and shear forces

Methodology Applied

Scientific EffectTurbulence: Turbulence

Data Source

PatentUS12571161B2Deflaking element for pulper

Publication Date: 2026.03.10 KADANT BLACK CLAWSON LLC

AI summary

A defibering and deflaking pulper has a defibering rotor-stator pair and a deflaking rotor-stator pair for processing a fiber-based material into smaller pieces. The defibering and deflaking pulper creates an impeller-produced vortical circulation that pulls the material through a defibering rotor-stator interface, where the material is broken down into smaller pieces, and then through a deflaking rotor-stator interface, where the smaller pieces are broken down into even smaller pieces. The defibering and deflaking pulper accumulates the defibered and deflaked material that passes through the defibering rotor-stator interface and the deflaking rotor-stator interface for further processing. This combination of defibering and deflaking in the defibering and deflaking pulper reduces plugging from larger pieces of the material and reduces downstream processing of the material, thus increasing productivity and reducing costs.