METHOD FOR PRODUCING A REFINER DISC SEGMENT

Abstract

A disc-type refiner segment and a production method thereof are provided for refining lignocellulosic material, comprising providing production data of the disc-type refiner segment supplying the production data to a 3D printer; 3D printing a pattern of the disc-type refiner segment; using the pattern of the disc-type refiner segment to generate a mold of the of the disc-type refiner segment; and molding or casting the disc-type refiner segment using the mold.

Claims

1. (canceled)

2. (canceled)

3. (canceled)

4. (canceled)

5. (canceled)

6. (canceled)

7. (canceled)

8. (canceled)

9. (canceled)

10. (canceled)

11. (canceled)

12. (canceled)

13. (canceled)

14. (canceled)

15. (canceled)

16. (canceled)

17. (canceled)

18. (canceled)

19. Method for producing a disc-type refiner segment for refining lignocellulosic material, comprising: providing production data of the disc-type refiner segment; supplying the production data to a 3D printer; 3D printing a pattern of the disc-type refiner segment; using the pattern of the disc-type refiner segment to generate a mold of the of the disc-type refiner segment; and molding or casting the disc-type refiner segment using the mold.

20. Method according to claim 19, wherein the disc-type refiner segment comprises at least a first part and a second part and wherein the patterns of the first and second parts of the disc-type refiner segment are formed separately.

21. Method according to claim 20, wherein the step of providing production data of the disc-type refiner segment comprises providing production data of the first and second parts of the disc-type refiner segment.

22. Method according to claim 20, wherein the step of supplying the production data to a 3D printer comprises supplying the production data of the first and second parts of the disc-type refiner segment to the 3D printer.

23. Method according to claim 20, wherein the step of 3D printing a pattern of the disc-type refiner segment comprises 3D printing a pattern of the first and second parts of the disc-type refiner segment.

24. Method according to claim 20, wherein the step of using the pattern of the disc-type refiner segment to generate a mold of the of the disc-type refiner segment comprises using the pattern of the first and second parts of the disc-type refiner segment to generate a first mold and a second mold of the first and second parts of the disc-type refiner segment.

25. Method according to claim 20, wherein the step of molding or casting the disc-type refiner segment using the mold comprises molding or casting the first and second parts of the disc-type refiner segment using the first and second molds.

26. Method for producing a disc-type refiner segment for refining lignocellulosic material, comprising: providing production data of the disc-type refiner segment; supplying the production data to a 3D printer; and 3D printing the disc-type refiner segment.

27. Method according to claim 26, wherein the disc-type refiner segment comprises at least a first part and a second part.

28. Method according to claim 27, wherein the step of providing production data of the disc-type refiner segment comprises providing production data of the first and second parts of the disc-type refiner segment.

29. Method according to claim 27, wherein the step of supplying the production data to a 3D printer comprises supplying the production data of the first and second parts of the disc-type refiner segment to the 3D printer.

30. Method according to claim 27, wherein the step of 3D printing the disc-type refiner segment comprises 3D printing the first and second parts of the disc-type refiner segment.

31. (canceled)

32. (canceled)

33. (canceled)

34. (canceled)

35. (canceled)

36. (canceled)

Description

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0034] The present invention is based on the use of a 3D printer to produce a model of a refiner segment. In one embodiment a refiner segment model is used to produce a mold, in which a refiner segment is molded or casted. More specifically, according to the disclosure, a refiner segment can be produced following manufacturing steps.

[0035] In one specific embodiment of the present disclosure, a 3D model of a first side, e.g. a front side, of a refiner segment is produced with a CAD program package, where the 3D refiner segment model created by the CAD program is a mathematical representation stored in a first data file with a suitable file format, e.g. a STL file. Then, a 3D model of a second side, e.g. a back side, of the refiner segment is produced with a CAD program package, where the 3D refiner segment model created by the CAD program is a mathematical representation stored in a second data file with a suitable file format, e.g. a STL file. Suitable CAD program packages are, for example, Pro/Engineer and SolidWorks. Optionally but preferably, the data on the first and second data files are checked for errors and imperfections with a suitable software program package, e.g. a program package provided by the company EOS e-manufacturing solutions. Besides correcting errors in the data files, it is important that all geometrical structures in the refiner segment models are reproducible in subsequent manufacturing steps and are suitable for such manufacturing steps, as will be further discussed below. Depending on the geometrical structures incorporated in the refiner segments and on the specific 3D printer and 3D printer software chosen, the data contained in the data files is mathematically sliced into layers, which can have a virtual thickness of, e.g., 0.01 mm. The mathematically sliced data files are then input into a suitable 3D printer package and a first side, e.g. a front side, of a refiner segment is printed using a 3D printer. Different 3D printing techniques can be employed, but a preferred technique is so-called direct metal laser sintering (DMLS), which utilizes an ytterbium (Yb) fiber laser fired into a bed of metal powder. Similarly, a second side, e.g. a back side, of the refiner segment by a 3D printing technique. The first and second sides of the refiner segment model are then used to create two mold halves which are put together to form a mold. The mold is typically made in sand, as is well-known in the art. In conventional manner, a refiner segment is then molded or casted in the mold. In practice, since several, e.g. 18-20, segments are needed for each refiner disc, and a pulp mill consumes several refiner discs pro year, many, e.g. several hundreds, of sand molds are produced from the two 3D printed sides of a refiner segment model.

[0036] From the above, it should be appreciated that the 3D refiner segment model as represented on the data file(s), should be suitable not only for 3D printing but also for forming molds and casting of refiner segments in these molds. Thus, the 3D refiner segment model should not only be free from errors, all geometrical shapes, e.g. corners, edges and angles, must be reproducible when producing the (sand) molds and subsequently when casting the final refiner segments in the molds. Thus, the 3D models must typically be carefully checked before they can be used in 3D printer, to produce a three-dimensional refiner segment model which in an effective manner can be used to produce a mold for casting of a refiner segment.

[0037] In one aspect of the disclosure, a refiner segment model, which comprises a front side and a back side, is provided by the use of a 3D printer. In a second aspect of the disclosure, a refiner segment is provided in a manufacturing process comprising the use of a 3D printer.