Refiner Element Wear-Resistant Layering for Pulp Processing
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Solution Overview
Problem
Current mechanical treatment systems for fibrous materials in the pulp and paper industry face challenges in energy efficiency and wear-related costs, with existing clothing designs and materials not fully optimizing energy use and wear resistance.
Innovation Solution
The treatment elements are applied in layers from liquid or solid materials and subjected to physical or chemical hardening processes, allowing for adaptable design and reduced material usage, with a core connected to the base body and a wear-resistant outer layer applied, enabling the use of cheaper materials and improved wear indication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If treatment elements are made entirely from expensive wear-resistant material, then wear resistance is improved, but manufacturing cost increases
Solution Approach 1:
The treatment element features a core made of inexpensive material and an outer wearing layer made of expensive wear-resistant material. This local differentiation applies the expensive material only where it is most needed (the surface subject to wear) while using cheaper material for the bulk structure, thereby reducing overall material cost while maintaining wear resistance.
Solution Approach 2:
The treatment element is constructed as a composite structure combining a core material with a wearing layer material. The core provides structural support and can be made from inexpensive materials, while the wearing layer provides the necessary wear resistance and is applied as a coating or cladding on the core surface.
2Productivity
If treatment elements are designed with complex shapes for optimized fiber treatment, then treatment effectiveness is improved, but manufacturing complexity increases
Solution Approach 1:
The treatment element is divided into a simple core structure and a separate wearing layer. The core can be manufactured as a simple geometric shape using conventional methods, while the wearing layer is applied subsequently to provide the complex surface profile needed for optimized fiber treatment. This segmentation separates the structural function from the treatment function.
Solution Approach 2:
The surface profile of the wearing layer can be precisely controlled by adjusting parameters such as layer thickness, material composition, and application conditions. This allows optimization of the treatment surface geometry without changing the core structure, enabling flexible adaptation to different treatment requirements while keeping manufacturing simple.
3Duration of action of stationary object
If more wear-resistant material is used, then service life is improved, but energy consumption increases
Solution Approach 1:
The expensive wear-resistant material is applied locally only on the outer surface where wear occurs, rather than throughout the entire treatment element. This reduces the total amount of wear-resistant material used and consequently reduces the energy required for mixing and handling, while still providing adequate wear protection to extend service life.
Solution Approach 2:
The wearing layer is designed as a replaceable or reconditionable component. When it becomes worn, it can be removed and a new layer applied to the core, rather than replacing the entire treatment element. This extends the effective service life of the core structure while minimizing the amount of expensive wear-resistant material needed at any one time.
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
This approach enhances wear resistance, reduces energy consumption, and allows for more flexible design, improving the fibrillation of fibers while minimizing the use of expensive materials, thus lowering operational costs and increasing the lifespan of treatment elements.
Implementation Method 1
The treatment elements are applied in layers from liquid or solid materials and are thereby subjected to a physical or chemical hardening or melting process
Implementation Method 2
If the material applied in layers is sintered or fused by means of a laser
Implementation Method 3
If the material applied in layers is sintered or fused by means of a laser
Data Source
Figure 1~2
Figure 3a~9
AI summary
The invention relates to a method for producing a garment (2, 3) for treating aqueous suspended fibrous material (1) in a treatment gap (4), consisting of a base body (5) with treatment elements (6) facing the gap (4). The manufacturing effort is to be reduced by applying the treatment elements (6) at least partially in layers from a liquid or solid material and subjecting them to a physical or chemical hardening or melting process.