Injection molding screening device and method
阅读说明:本技术 注塑成型的筛分装置及方法 (Injection molding screening device and method ) 是由 基斯·霍夫斯基 于 2018-07-06 设计创作,主要内容包括:提供了用于振动筛分机的筛分构件(16)、筛分组件(10)、制造筛分构件和组件的方法以及筛分物料的方法,振动筛分机包含注塑成型材料的利用。提供了注塑成型筛网元件的应用,尤其用于:改变筛分表面(11)的构造;加快以及简化筛网组件的制造;以及结合筛网组件的突出的机械性能和电学性能,包括韧性、耐磨和耐化学性能。本发明实施例使用热塑性注塑成型材料。(Screen members (16), screen assemblies (10), methods of making screen members and assemblies, and methods of screening materials for vibratory screening machines that incorporate the use of injection molded materials are provided. There is provided the use of an injection moulded screen element, particularly for: -modifying the configuration of the screening surface (11); expedite and simplified manufacture of screen assemblies; and outstanding mechanical and electrical properties, including toughness, abrasion and chemical resistance properties, combined with screen assemblies. Embodiments of the present invention use thermoplastic injection molding materials.)
1. A screen assembly, comprising:
a sub-grid; and;
a screen element attached to the subgrid, the screen element having a screening surface comprising:
a mesh, being an elongated slot having a substantially uniform width W and a substantially uniform length L, wherein the width W of the mesh is about 40 microns W200 microns and the length L of the mesh is about 0.7 mm L2 mm; and
a surface element for separating the mesh, the surface element having a thickness T, the thickness T being about 70 microns T400 microns;
wherein the screen assembly has an open screening area of about 5% to about 35% of the total screening surface area.
2. The screen assembly of claim 1 wherein:
the thickness of the surface element is T ≈ 356 microns;
the length of the sieve pore is L which is approximately equal to 1.9 mm; and
the open screen area varies from about 6% to about 24% as the width W of the screen aperture varies from about 45 microns to 180 microns.
3. The screen assembly of claim 1 wherein:
the thickness of the surface element is T ≈ 178 microns;
the length of the sieve pore is L which is approximately equal to 1.2 mm; and
the open screen area varies from about 10% to 28% as the width W of the screen aperture varies from about 45 microns to 180 microns.
4. The screen assembly of claim 1 wherein:
the thickness of the surface element is T ≈ 127 micrometers;
the length of the sieve mesh is L which is approximately equal to 0.8 mm; and
the open screen area varies from about 12% to about 32% as the width of the screen openings varies from about 45 microns to 180 microns.
5. The screen assembly of claim 1 wherein:
the thickness of the surface element is T ≈ 76 microns;
the length of the sieve pore is L which is approximately equal to 0.7 mm; and
the open screen area varies from about 13% to about 33% as the width of the screen openings varies from about 45 microns to 180 microns.
6. A screen assembly as claimed in claim 1, wherein the screen element is a single thermoplastic injection moulding.
7. The screen assembly of claim 1 further comprising:
a plurality of subgrids secured together to form the screen assembly having a screening surface with a range of about 0.4m2To 6.0m2Total screening area of.
8. A screen assembly as claimed in claim 7, wherein a subgrid includes at least one base member having fasteners which mate with fasteners of other base members of other subgrids to secure the subgrids together.
9. A screen assembly as claimed in claim 8, wherein the fasteners comprise clips and clip apertures which snap into place to securely attach the subgrids together.
10. A screen assembly as claimed in claim 9, wherein the clip comprises at least three extension members which engage with clip apertures to securely attach sub-grids together.
11. A screen assembly as claimed in claim 9, wherein the clip comprises a central extension member which engages with a clip aperture to securely attach the subgrids together.
12. A screen assembly, comprising:
a plurality of screen elements; and
a plurality of subgrids, wherein each of the plurality of subgrids has at least one base member with clips that mate with clip holes of other base members of other subgrids to secure the subgrids together,
wherein at least one screen element is secured to each sub-grid, and
wherein the clip includes at least three extension members that engage the clip apertures.
13. The screen assembly of claim 12 wherein the screen assembly has a range of about 0.4m2To 6.0m2Total screening area of.
14. The screen assembly of claim 12 wherein the screen assembly has an open screening area of about 5% to about 35% of the total screening surface area.
15. A method of making a screen assembly, the method comprising:
manufacturing a subgrid having a grid framework with grid holes and at least one base member having clips that mate with clip holes of other base members of other subgrids to secure the subgrids together, the clips having at least three extension members that engage the clip holes;
injection molding a screen element having a screening surface, the screening surface comprising:
a screen aperture that is an elongated slot having a substantially uniform width W and a substantially uniform length L, wherein the width W is about 40 microns ≦ W ≦ 200 microns and the length L is about 0.7 mm ≦ L ≦ 2 mm; and
a surface element for a separation screen, the surface element having a thickness T, wherein the thickness T is about 70 microns T400 microns;
attaching the screen element to the subgrid; and
securing a plurality of subgrids together by engaging clips and clip apertures to form a screen assembly having an open screening area that is about 5% to about 35% of a total area of the screening surface.
Technical Field
The present disclosure relates generally to material screening. More particularly, the present disclosure relates to screen members, screen assemblies, methods of making screen members and assemblies, and methods of screening material.
Background
Material screening includes the use of vibratory screening machines. Vibratory screening machines provide a motive force that activates an installed screen to separate material placed on the screen to a desired degree. Oversized material is separated from undersized material. Over time, the screens wear and need to be replaced. The screen is therefore designed to be replaceable.
Replacement screen assemblies must be securely attached to the vibratory screening machine and are required to withstand large vibratory forces. Replacement screens may be attached to the vibratory screening machine by tension members, compression members, or clamping members.
Replacement screen assemblies are typically made of metal or thermoset polymers. The material and construction of replacement screens are directed to screening applications. For example, metal screens are commonly used in wet applications in the oil and gas industry due to their relative durability and fine screening capabilities. However, conventional thermoset polymer-based screens (e.g., molded polyurethane screens) are less durable and may not withstand the harsh conditions of such wet applications, and are therefore commonly used in dry applications, such as in mining applications.
The manufacture of thermoset polymeric screens is relatively complex, time consuming and prone to error. Typical thermoset polymer type screens used with vibratory screening machines are manufactured by chemically reacting separate liquids (e.g., polyester, polyether, and curing agents) and then curing the mixture in a mold for a period of time. This process can be very difficult and time consuming when making screens with fine mesh openings, for example, about 43 microns to about 100 microns. In fact, in order to form fine openings in the screening surface, the passage of the liquid through the die must be very small (e.g. around 43 microns), and in general, the liquid cannot reach all the holes of the die. Therefore, close attention to pressure and temperature is often required to perform complex procedures. Since a relatively large single screen (e.g., 2 feet by 3 feet or more) is made with a mold, one defect (e.g., a hole, i.e., where liquid does not reach) will destroy the entire screen. Thermoset polymer screens are typically manufactured by molding the entire screen assembly structure into one large screen assembly having a screen opening size of between about 43 microns and 4000 microns. The screening surface of conventional thermoset polymer screens typically has a uniform, flat structure.
Thermoset polymer type screens are relatively flexible and are typically secured to vibratory screening machines using tension members that pull the sides of the thermoset polymer screen apart from each other and hold the bottom surface of the thermoset polymer screen against the surface of the vibratory screening machine. To prevent deformation when tensioned, thermoset polymer components may be molded with aramid fibers in the direction of the tension (see U.S. Pat. No. 4,819,809). If a compressive force is applied to the side edges of a particular thermoset polymer screen, it will bend or curl, thereby rendering the screening surface relatively ineffective.
Unlike thermoset polymer screens, metal screens are rigid and can be compressed or tensioned on a vibratory screening machine. Metal screen assemblies are typically made from multiple metal assemblies. The manufacture of metal screen assemblies typically includes: making a screen material, typically a three-layer woven steel mesh; making a perforated metal base plate; and bonding the screen material to the perforated metal base plate. The wire cloth layer may be finely woven with pores ranging from about 30 to 4000 micrometers. The entire screening surface of a conventional metal assembly is typically a relatively uniform flat structure or a relatively uniform corrugated structure.
The key to the screening performance of screen assemblies (thermoset polymer assemblies and metal type assemblies) for vibratory screening machines is the size of the apertures on the screening surface, the structural stability and durability of the screening surface, the structural stability of the entire unit, the chemical properties at which the unit assembly behaves in different temperature environments, and the ability. Disadvantages of conventional metal components include lack of structural stability and durability of the screening surface formed by the woven mesh, clogging of the screening surface (particles clogging the screen openings), the weight of the overall structure, time and cost to manufacture or purchase each component of the associated component, and assembly time and cost. Since wire cloth is often outsourced by the wire mesh manufacturer and is often purchased from employees or wholesalers, quality control can be extremely difficult and wire cloth often presents problems. Defective wire cloths can cause screening performance problems and require constant control and inspection.
One of the biggest problems with conventional metal components is clogging. The new metal screen may initially have a relatively large open screening area, but over time, as the screen is exposed to particles, the screening openings become blocked (i.e., plugged) and the open screening area, as well as the effectiveness of the screen itself, decreases relatively quickly. For example, a 140 mesh screen assembly (with three layers of screen cloth) may have an initial open screening area of 20% -40%. However, with the use of screens, the open screening area may be reduced by 50% or more.
Conventional metal screen assemblies also reduce the amount of open screening area due to their construction, including adhesives, cauls, plastic sheets bonded by wire cloth layers, and the like.
Another major problem with conventional metal assemblies is screen life. Conventional metal components typically do not fail due to grinding, but rather fail due to fatigue. That is, the wires of the woven wire cloth actually break due to the up-and-down movement during being subjected to a vibration load.
Disadvantages of conventional thermoset polymer screens also include lack of structural stability and durability. Other disadvantages include the inability to withstand compressive type loads and the inability to withstand high temperatures (e.g., thermoset polymer type screens typically begin to fail or present performance problems at temperatures above 130 degrees fahrenheit, particularly screens having fine pores, e.g., on the order of 43 to 100 microns). In addition, as mentioned above, the manufacturing process is complex, time consuming and prone to error. Furthermore, the molds used to make thermoset polymer screens are expensive, and any defects or slightest damage will destroy the entire mold and require replacement, which can result in expensive down time in the manufacturing process.
Another disadvantage of conventional metal and thermoset polymer screens is the limitation of the screen surface configuration. Existing screening surfaces, whether flat or undulating, are manufactured with relatively uniform screen opening sizes and relatively uniform surface structures.
The conventional polymeric screen (also referred to as a conventional polymeric screen, an existing polymeric screen, a typical polymeric screen, or a simple polymeric screen) referenced in U.S. provisional application No. 61/652,039 refers to the conventional thermosetting polymeric screen described in U.S. provisional patent application No. 61/714,882, herein conventional thermosetting polymeric screen (also referred to herein as a conventional thermosetting polymeric screen, an existing thermosetting polymeric screen, a typical thermosetting polymeric screen, or a simple thermosetting screen in this document and in U.S. provisional patent application No. 61/714,882). Thus, the conventional polymeric screens referenced in U.S. provisional application No. 61/652,039 are the same as the conventional thermosetting polymeric screens referenced herein and in U.S. provisional patent application No. 61/714882, and can be manufactured with extremely small mesh sizes (as in the U.S. provisional patent application No. 61/714,882 herein), but suffer from all of the disadvantages of conventional thermosetting polymeric screens (as in the U.S. provisional patent application No. 61/714,882 herein), including lack of structural stability and durability, inability to withstand compressive type loads, inability to withstand high temperatures, and complex, time-consuming, error-prone manufacturing processes.
There is a need for multi-functional and improved screening members, screen assemblies, methods of making the screening members and assemblies, and methods of screening materials for vibratory screening machines that incorporate the use of injection molded materials (e.g., thermoplastics) with improved mechanical and chemical properties.
Disclosure of Invention
The present disclosure is an improvement over existing screen assemblies and methods of screening and manufacturing screen assemblies. The present invention provides extremely versatile and improved screening members, screen assemblies, methods of making screening members and assemblies, and methods for screening materials for vibratory screening machines that incorporate the use of injection molded materials having improved properties, including mechanical and chemical properties. In a particular embodiment of the invention, a thermoplastic is used as the material for the injection molding. The present invention is not limited to thermoplastic injection molding materials, but other materials having similar mechanical and/or chemical properties may be used in embodiments of the present invention. In an embodiment of the invention, a plurality of injection molded screen elements are securely attached to the subgrid structure. The subgrids are fastened together to form a screen assembly structure having a screening surface that includes a plurality of screen elements. The use of injection molded screen elements by the various embodiments herein provides, among other things, for altering screening surface configurations; fast and relatively simple screen assembly manufacturing; and excellent mechanical, chemical and electrical properties of the screen assembly, including toughness, abrasion resistance and chemical resistance.
Embodiments of the present invention include screen assemblies configured to have relatively large open screening areas while having small structurally stable screen apertures for fine vibratory screening applications. In embodiments of the present invention, the screen openings are very small (e.g., as small as about 43 microns) and the screen elements are large enough (e.g., one inch by one inch, one inch by two inches, two inches by three inches, etc.) that they actually assemble into a complete screen assembly screening surface (e.g., two feet by three feet, three feet by four feet, etc.). The manufacture of small mesh for fine screening applications requires injection molding of very small structural members that actually form the mesh. These structural members are injection molded to be integrally formed with the screen element structure. Importantly, the structural members are small enough (e.g., they screen surface widths of about 43 microns in a particular application) to provide an effective overall open screening area and form part of an overall screen element structure that is large enough (e.g., two inches by three inches) to actually assemble into a relatively large overall screening surface (e.g., two feet by three feet).
In one embodiment of the invention, the thermoplastic material is injection moulded to form the screening element. Thermoplastic materials have not previously been used in the manufacture of vibratory screens having fine size openings (e.g., about 43 microns to about 1000 microns), because injection molding of thermoplastic materials has made it difficult, if not impossible, to manufacture a single relatively large vibratory screening structure having fine openings and to obtain the open screening area necessary for competitive performance in vibratory screening applications.
According to an embodiment of the present disclosure, a screen assembly is provided: structurally stable and capable of withstanding various loads including compression, tension and clamping; can bear larger vibration force; comprising a plurality of injection molded screen elements which, due to their relatively small size, can be manufactured to extremely small screen sizes (having diameters as small as about 43 microns); eliminating the need for wire cloth; the weight is light; the circulation can be carried out; the assembly is simple; a variety of different configurations can be made, including a variety of screen opening sizes in the screen, a variety of screening surface configurations, e.g., a variety of engagement of flat and undulating portions; and can be made according to the specific application material and nanomaterial. In addition, each screen assembly may be customized to a particular application, and different screen sizes and configurations may be easily manufactured according to the specifications provided by the end user. Embodiments of the present invention may be applied in a variety of applications, including wet and dry applications, and in a variety of industries. The present invention is not limited solely to the oil and gas industry and the mining industry. Embodiments of the present disclosure may also be used in any industry where it is desirable to separate materials using vibratory screening machines, including pulp and paper, chemical, pharmaceutical, and other industries.
In an exemplary embodiment of the present invention, a screen assembly is provided that substantially improves the screening of materials with thermoplastic injection molded screen elements. A plurality of thermoplastic polymer injection molded screen elements are securely attached to the subgrid structure. The subgrids are secured together to form a screen assembly structure having a screening surface that includes a plurality of screen elements. Each screen element and each subgrid may have different shapes and configurations. Thermoplastic injection molding of individual screen elements allows for precise fabrication of screen openings, which may have diameters as small as about 43 microns. The grid framework may be substantially rigid and may provide durability against damage or deformation when secured to the vibratory screening machine under substantial vibratory loads to which it is subjected. In addition, when assembled into a complete screen assembly, the subgrids are strong enough to withstand not only vibratory loads, but also the forces required to secure the screen assembly to the vibratory screening machine, including large compressive, tensile, and/or clamping loads. In addition, the apertures in the subgrid structurally support the screen elements and transmit vibrations from the vibratory screening machine to the elements forming the screening apertures, thereby optimizing screening performance. The screen assembly, the subgrid, and/or any other component of the screen assembly may include nanomaterials and/or glass fibers that provide durability and strength, among other benefits.
In accordance with an exemplary embodiment of the present invention, a screen assembly is provided having a screen element including a screen element screening surface having a series of screen apertures, and a subgrid including a plurality of elongated structural members forming a grid frame having grid apertures. The screen element spans the at least one grid aperture and is attached to the top surface of the subgrid. A plurality of individual subgrids are secured together to form a screen assembly and the screen assembly has a continuous screen assembly screening surface having a plurality of screen element screening surfaces. The screen element includes generally parallel end portions and generally parallel side edge portions generally perpendicular to the end portions. The screen element also includes a first screen element support member and a second screen element support member orthogonal to the first screen element support member. The first screen element support member extends between the ends, generally parallel to the side margins. The second screen element support member extends between the side edge portions, generally parallel to the end portions. The screen element includes a first series of reinforcement members generally parallel to the side margins and a second series of reinforcement members generally parallel to the end margins. The screen element screening surface includes screen surface elements that form the screen openings. The end portions, the side edges, the first and second support members, and the first and second series of reinforcement members structurally stabilize the screen surface elements and the mesh openings. The screen element is formed from a single thermoplastic injection molded piece.
The mesh may be rectangular, square, circular, oval or any other shape. The screen surface elements may be parallel to the ends and form the mesh. The screen surface elements may also be perpendicular to the ends and form the mesh. Different combinations of rectangular, square, circular and oval apertures (or other shapes) may be combined, and may be parallel and/or perpendicular to the ends, depending on the shape used.
The screen surface elements may run parallel to the ends and may be elongated members forming the mesh. The mesh may be elongated slots having a distance of about 43 microns to about 4000 microns between inner surfaces of surface elements of adjacent screens. In certain embodiments, the screen openings may have a distance of about 70 microns to about 180 microns between the inner surfaces of adjacent screen surface elements. In other embodiments, the screen openings may have a distance between inner surfaces of adjacent screen surface elements of approximately 43 microns to approximately 106 microns. In embodiments of the present invention, the mesh may have a width and a length, and the width may be about 0.043 mm to about 4 mm and the length may be about 0.086 mm to about 43 mm. In certain embodiments, the ratio of the width to the length may be about 1:2 to about 1: 1000.
Multiple subgrids of different sizes may be combined to form a screen assembly support structure for a screen element. Alternatively, a single subgrid may be injection molded or otherwise constructed to form the entire screen assembly support structure for a plurality of individual screen elements.
In embodiments using multiple subgrids, a first subgrid may include a first base member having a first fastener that mates with a second fastener of a second base member of a second subgrid, the first and second fasteners securing the first and second subgrids together. The first fastener may be a clip and the second fastener may be a clip hole, wherein the clip snaps into the clip hole and securely attaches the first and second subgrids together.
The first and second screen element support members and the screen element ends may include a screen element attachment arrangement configured to mate with a subgrid attachment arrangement. The subgrid attachment arrangement may include an elongated attachment member, and the screen element attachment arrangement may include attachment holes that mate with the elongated attachment member, the attachment holes securely attaching the screen element to the subgrid. A portion of the elongated attachment member may be configured to extend through the screen element attachment aperture and slightly above the screen element screening surface. The attachment holes may include tapered holes or may simply include holes without any taper. The elongated attachment members above the screening surface of the screen element may melt and fill the tapered holes, securing the screen element to the subgrid. Alternatively, the parts of the elongated attachment members extending through the holes in the screening element screening surface and extending above the holes of the screening element screening surface may be melted to form beads on the screening element screening surface and fasten the screen element to the subgrid.
The elongated structural member may include substantially parallel sub-grid end members and substantially parallel sub-grid side members substantially perpendicular to the sub-grid end members. The elongated structural member may further comprise a first sub-grid support member and a second sub-grid support member orthogonal to the first sub-grid support member. The first sub-grid support member may extend between the sub-grid end members and may be substantially parallel to the sub-grid end members. The second sub-grid support member may extend between the side edge members of the sub-grid and may be substantially parallel to the end members of the sub-grid and substantially perpendicular to the side edge members of the sub-grid.
The grid frame may include first and second grid frames forming first and second grid holes. The screen elements may include a first screen element and a second screen element. The subgrid may have a ridge portion and a base portion. The first and second grid frameworks may include first and second corner faces forming a peak at the ridge portion and extending downward from the peak portion to the base portion. The first and second screen elements may span the first and second angular faces, respectively.
In accordance with an exemplary embodiment of the present invention, a screen assembly is provided having a subgrid including a screen element screening surface having a series of apertures and including a plurality of elongated structural members forming a grid frame having grid apertures. The screen element spans at least one of the grid holes and is secured to the top surface of the subgrid. The plurality of subgrids are secured together to form a screen assembly having a continuous screen assembly screening surface comprised of a plurality of screen element screening surfaces. The screen element is a single thermoplastic injection molded piece.
The screen element may include substantially parallel end portions and substantially perpendicular, substantially parallel side edge portions. The screen element may also include a first screen element support member and a second screen element support member orthogonal to the first screen element support member. The first screen element support member may extend between the ends and may be substantially parallel to the side margins. The second screen element support member may extend between the side margins and may be substantially parallel to the end portions. The screen element may include a first series of reinforcement members substantially parallel to the side margins and a second series of reinforcement members substantially parallel to the end margins. The screen element may comprise an elongate screen surface element running parallel to the end portions and forming the screening openings. The end portions, the side edges, the first and second support members, and the first and second series of reinforcement members may structurally stabilize the screen surface elements and the mesh openings.
The first and second series of reinforcement members may have a thickness less than the thickness of the end portions, the side edges and the first and second screen element support members. The end and side edges and the first and second screen element support members may form four rectangular areas. The first and second series of reinforcement members may form a plurality of rectangular support grids within the four rectangular areas. The openings have a width between the inner surfaces of the surface elements of each screen of about 43 microns to about 4000 microns. In certain embodiments, the screen openings may have a width of about 70 microns to about 180 microns between the inner surfaces of each screen surface element. In other embodiments, the screen openings may have a width of about 43 microns to about 106 microns between the inner surfaces of each screen surface element. In embodiments of the present invention, the mesh may have a width of about 0.043 mm to about 4 mm and a length of about 0.086 mm to about 43 mm. In certain embodiments, the ratio of the width to the length may be about 1:2 to about 1: 1000.
The screen element may be flexible.
The sub-grid end members, the sub-grid side members and the first and second sub-grid support members may form eight rectangular grid holes. The first screen element may span four grid apertures and the second screen element may span the other four apertures.
The central portion of the screening surface of the screen element may bend slightly when subjected to a load. The subgrid may be substantially rigid. The subgrid may also be a single thermoplastic injection molded part. At least one of the subgrid end members and the subgrid side members may include fasteners configured to mate with fasteners of other subgrids, which may be clips and clip holes that snap into place and securely connect the subgrids together.
The subgrid may include generally parallel triangular end pieces, a triangular intermediate piece generally parallel to the triangular end pieces, first and second intermediate supports generally perpendicular to and extending between the triangular end pieces, first and second base supports generally perpendicular to and extending between the triangular end pieces, and a central ridge generally perpendicular to and extending between the triangular end pieces. The first rim of the triangular end piece, the triangular middle piece and the first middle support, the first base support and the central spine may form a first top surface of a subgrid having a first series of grid holes. The second rim of the triangular end block, the triangular middle piece and the second middle support, the second base support and the central spine may form a second top surface of the subgrid, the subgrid having a second series of grid holes. The first top surface may slope from the central ridge to the first substrate support and the second top surface may slope from the central ridge to the second substrate support. The first screen element and the second screen element may span the first series and the second series of grid apertures, respectively. The first rim of the triangular end piece, the triangular middle piece, the first middle support, the first base support, and the central ridge may comprise a first subgrid attachment arrangement configured to securely mate with a first screen element attachment arrangement of a first screen element. The second rim of the triangular end piece, the triangular middle piece, the second middle support, the second base support, and the central ridge may comprise a second subgrid attachment arrangement configured to securely mate with a second screen element attachment arrangement of a second screen element. The first and second subgrid attachment arrangements may include elongated attachment members, and the first and second screen element attachment arrangements may include attachment apertures that cooperate with the elongated attachment members to securely attach the first and second screen elements to the first and second subgrids, respectively. A portion of the elongated attachment member may extend through the screen element attachment apertures and slightly above the first and second screen element screening surfaces.
The first screen member and the second screen member may each include a generally parallel end portion and a side edge portion generally parallel to the end portion. The first and second screen elements may each include a first screen element support member extending between the end portions and approximately parallel to the side rim portions and a second screen element support member orthogonal to the first screen element support member extending between the side rim portions, which may be approximately parallel to the end portions. The first and second screen elements may each include a first series of reinforcement members generally parallel to the side margins and a second series of reinforcement members generally parallel to the end margins. The first and second screen elements may each include elongated screen surface elements running parallel to the end portions and forming the screening openings. The end portions, the side edges, the first and second support members, and the first and second series of reinforcement members may structurally stabilize the screen surface elements and the mesh openings.
One of the first and second base supports may include a fastener that secures the plurality of subgrids together, and the fastener may be a clip and clip hole that snaps into place and securely secures the subgrids together.
The screen assembly may include first, second, third and fourth screen elements. The first series of grid holes may be eight holes formed by the first rim of the triangular end piece, the triangular middle piece, the first middle support, the first base support, and the central ridge. The second series of grid holes may be eight holes formed by the second rim of the triangular end piece, the triangular middle piece, the second middle support, the second base support and the central ridge. The first screen element may span four grid apertures of the first series of grid apertures and the second screen element may span the other four grid apertures of the first series of grid apertures. The third screen element may span four grid apertures of the second series of grid apertures and the fourth screen element may span the other four grid apertures of the second series of grid apertures. The central portion screening surfaces of the first, second, third and fourth screen elements may be slightly curved when subjected to a load. The subgrid may be substantially rigid and may be a single thermoplastic injection molded part.
According to an exemplary embodiment of the present invention, a screen assembly is provided having a screen element including a screen element screening surface with screen apertures and a subgrid including a grid frame with grid apertures. The screening elements span the grid holes and are attached to the surface of the subgrids. The plurality of subgrids are secured together to form a screen assembly having a continuous screen assembly screening surface that includes a plurality of screen element screening surfaces. The screen element is a thermoplastic injection molded part.
The screen assembly may also include a first thermoplastic injection molded screen element and a second thermoplastic injection molded screen element, and the grid frame may include first and second grid frames forming first and second grid apertures. The subgrid may include a ridge portion and a base portion, and the first and second grid frameworks include first and second corner faces that form a peak at the ridge portion and extend downward from the peak portion to the base portion. The first screen member and the second screen member may span the first and second angular faces, respectively. The first and second corner faces may comprise sub-grid attachment means configured to fixedly mate with the screen element attachment means. The subgrid attachment arrangement may include an elongated attachment member and the screen element attachment arrangement may include an aperture that cooperates with the elongated attachment member to securely connect the screen element to the subgrid.
The subgrid may be substantially rigid and may be a single thermoplastic injection molded part. A portion of the base section may include first and second fasteners that secure the subgrid to third and fourth fasteners of another subgrid. The first and third fasteners may be clips and the second and fourth fasteners may be clip apertures. The clip may snap into the clip hole and securely attach the subgrid and then another subgrid together.
The subgrids may form a concave structure and the screening surface of the continuous screen assembly may be concave. The subgrids may form a flat structure and the screening surface of the continuous screen assembly may be flat. The subgrids may form a convex structure and the screening surface of the continuous screen assembly may be convex.
The screen assemblies may be configured to form a preformed concave shape when placed on the vibratory screening machine under a compressive force exerted by a compression assembly of the vibratory screening machine against at least one side member of the vibratory screen assembly. The prefabricated concave shape can be determined according to the surface shape of the vibration screening machine. The screen assembly may have a mating surface that mates with a surface of the vibratory screening machine, which may be rubber, metal (e.g., steel, aluminum, etc.), composite, plastic material, or any other suitable material. The screen assembly may include a mating surface configured to interface with a mating surface of the vibratory screening machine to guide the screen assembly into a fixed position on the vibratory screening machine. The mating surface may be formed in a portion of at least one of the subgrids. The screen assembly mating surfaces may be recesses formed in the corners of the screen assembly or may be recesses formed in the middle of the side edges of the screen assembly. The screen assembly may have an arcuate surface configured to mate with a concave surface of a vibratory screening machine. The screen assembly may have a substantially rigid structure that does not substantially deflect when secured to the vibratory screening machine. The screen assembly may include a screen assembly mating surface configured to form a preformed concave shape when subjected to the compressive forces of the vibratory screen machine member. The screen assembly mating surface may be shaped to attach to a mating surface of the vibratory screening machine so that the screen assembly may be guided to a pre-manufactured location on the vibratory screening machine. The screen assembly may include a load bar attached to a rim surface of a subgrid of the screen assembly. The load bar may be configured to distribute the load over the surface of the screen assembly. The screen assembly may be configured to form a preformed concave shape when the screen assembly is subjected to a compressive force exerted by a compression member of the vibratory screening machine against a load bar of the vibratory screen assembly. The screen assembly may have a concave shape and may be configured to deflect and form a preformed concave shape when subjected to the compressive forces of the vibratory screen machine member.
The first set of subgrids may form a center support frame assembly having a first fastener arrangement. The second set of sub-grids may form a first end support frame assembly having a second fastener arrangement. The third set of subgrids may form a second end support frame assembly having a third fastener arrangement. First, second and third fastener means may secure the first and second end support frames to the center support assembly. The side edges of the first end support frame assembly may form a first end of the screen assembly along the surface. The side edges of the second end support frame means may form the second end of the screen assembly along the surface. Each end face of the first and second end support frame assemblies and the central support frame assembly may be accumulated to form a first side and a second side of the completed screen assembly. The first and second sides of the screen assembly may be substantially parallel and the first and second end faces of the screen assembly may be substantially parallel and substantially perpendicular to the sides of the screen assembly. The side of the screen assembly may include a fastener configured to engage at least one of the adhesive strip and the load spreading strip. The sub-grids may include sides, and the first and second end support frame assemblies and the center support frame assembly may each form a concave shape when the individual sub-grids are secured together to form the first and second end support frame assemblies and the center support frame assembly. The subgrid may include side surface shapes that form a convex shape when the individual subgrids are secured together to form the first and second end support frame assemblies and the central support frame assembly.
The screen element may be attached to the subgrid by at least one of mechanical means, adhesive, heat staking and ultrasonic welding.
According to an exemplary embodiment of the present invention, a screen element is provided having a screen element screening surface with a series of screen openings formed therein; a pair of substantially parallel end portions; a pair of substantially parallel side edge portions substantially perpendicular to the end portions; a first screen element support member; a second screen element support member orthogonal to the first screen element support member, the first screen element support member extending between the end portions and generally parallel to the side edge portions, the second screen element support member extending between the side edge portions and generally parallel to the end portions and generally parallel to the side edge portions; a first series of reinforcement members generally parallel to the side margins; and a second series of reinforcement members generally parallel to the end portions. The screen surface elements run parallel to the end portions. The end portions, the side edge portions, the first and second support members, the first and second series of reinforcement members structurally stabilize the screen surface member and the screen apertures, and the screen element is a single thermoplastic injection molded piece.
In accordance with an exemplary embodiment of the present invention, a screen element is provided having a screen element screening surface with screen surface elements forming a series of screening openings; a pair of substantially parallel end portions; and a pair of substantially parallel side edge portions substantially perpendicular to the end portions. The screen element is a thermoplastic injection molded part.
The screen element may also have a first screen element support member; a second screen element support member orthogonal to the first screen element support member, the first screen element support member extending between the ends substantially parallel to the side margins, the second screen element support member extending between the side margins substantially parallel to the ends; a first series of reinforcement members generally parallel to the side margins; and a second series of reinforcement members generally parallel to the end portions. The screen surface elements may run parallel to the ends. In certain embodiments, the screen surface elements are configured to run perpendicular to the ends. The end portions, the side edge portions, the first and second support members, and the first and second series of reinforcement members may structurally stabilize the screen surface member and the screen apertures.
The screen element may also have a screen element attachment arrangement integrally formed with the screen element and configured to mate with the subgrid attachment arrangement. The plurality of subgrids may form a screen assembly, and the screen assembly may have a continuous screen assembly screening surface that includes a plurality of screen element screening surfaces.
According to an exemplary embodiment of the present invention, there is provided a method of manufacturing a screen assembly for screening material, including: determining a screen assembly performance specification for the screen assembly; determining a screen element screening requirement for a screen element according to a screen assembly performance specification, the screen element including a screen element screening surface having a screen aperture; determining a screen configuration according to a screen assembly performance specification, the screen configuration including screen elements arranged in at least one of a flat configuration and a non-flat configuration; injection molding the screen element from a thermoplastic material; fabricating a subgrid configured to support the screen elements, the subgrid having a grid frame with grid apertures, wherein at least one screen element spans at least one grid aperture and is secured to a subgrid top surface, the top surface of each subgrid including at least one of a flat surface and a non-flat surface that receives the screen element; attaching a screen element to the subgrid; attaching a plurality of subgrid assemblies together to form an end screen frame and a middle screen frame; attaching the end screen frame to the intermediate screen frame to form a screen frame structure; attaching a first adhesive strip to a first end of the screen frame structure; and attaching a second adhesive strip to a second end of the screen frame structure to form a screen assembly having a continuous screen assembly screening surface comprised of a plurality of screen element screening surfaces.
The screen assembly performance specifications may include at least one of size, material requirements, open screening area, cut points, and capacity requirements for screening applications. The handle may be attached to the adhesive strip. A label may be attached to the adhesive strip, which may include a performance specification for the screen assembly. At least one of the screen element and the subgrid may be a single thermoplastic injection molded part. The thermoplastic material may comprise a nanomaterial. The subgrid may include at least one base member having fasteners that mate with and secure the subgrids together with the fasteners of the other base members of the other subgrids. The fasteners may be clips and clip holes that snap into place and securely connect the subgrids together.
According to an exemplary embodiment of the present invention, a method of manufacturing a screen assembly for screening material is provided by injection molding a screen member having a thermoplastic material, the screen member including a screen member screening surface having screen openings; making a subgrid supporting a screen element, the subgrid having a grid framework with grid apertures, the screen element spanning at least one grid aperture; securing a screen element to a top surface of the subgrid; attaching a plurality of subgrid assemblies together to form a screen assembly having a continuous screen assembly screening surface comprised of a plurality of screen element screening surfaces. The method may also include attaching a first adhesive strip to the first end of the screen assembly and attaching a second adhesive strip to the second end of the screen assembly. The first and second adhesive strips may bond the subgrid together. The adhesive strips may be configured to distribute a load to the first and second ends of the screen assembly. The thermoplastic material may comprise a nanomaterial.
In accordance with an exemplary embodiment of the present disclosure, a method of screening material is provided by attaching a screen assembly to a vibratory screening machine, the screen assembly including a screen element having a series of screening apertures forming a screening surface of the screen element, and a subgrid including a plurality of elongated structural members forming a grid frame having grid apertures. The screen elements span the grid holes and are secured to the top surface of the subgrid. A plurality of subgrids are secured together to form a screen assembly. The screen assembly has a continuous screen assembly screening surface comprised of a plurality of screen element screening surfaces. The screen element is a single thermoplastic injection molded part. The material is screened using a screen assembly.
According to an exemplary embodiment of the present invention, a method of screening material is provided that includes attaching a screen assembly to a vibratory screening machine and forming a top screening surface of the screen assembly into a concave shape. The screen assembly includes a screen element having a series of apertures forming a screening surface of the screen assembly and a subgrid including a plurality of elongated structural members forming a grid framework having grid apertures. The screen elements span the grid holes and are secured to the top surface of the subgrid. The plurality of subgrids are secured together to form a screen assembly having a continuous screen assembly screening surface comprised of a plurality of screen element screening surfaces. The screen element is a single thermoplastic injection molded part. The material is screened using a screen assembly.
According to an exemplary embodiment of the present invention, there is provided a screen assembly comprising a screen element having a first attachment device; and a sub-grid cell having second adhesive means. The first and second adhesive means may be different materials. At least one of the first and second attachment means is activatable so that the screen element and subgrid may be secured together. The screen element is a single thermoplastic injection molded part.
The first adhesive means may be a plurality of pockets on the bottom surface of the screen element and the second adhesive means may be a plurality of fusion bars on the top surface of the subgrid. The screen elements are micro-molded with mesh openings between about 40 microns to about 1000 microns. The pocket may be an elongate pocket. The height of the fusion rod may be slightly greater than the depth of the pocket. The depth of the pocket may be about 0.05 inches and the height of the fusion bar about 0.056 inches. The width of the fusion rod may be slightly less than the width of the pocket.
The screen element may comprise thermoplastic polyurethane. The subgrid may include nylon. The screen assembly may include additional screen elements and sub-grids secured together, wherein a plurality of the sub-grids are secured together. The screen member may have a plurality of openings in the form of elongated slots having a width and a length, the openings having a width between the inner surfaces of each of the screen surface members of about 43 microns to about 1000 microns. The screen element may be attached to the subgrid by laser welding. The weld between the screen element and the subgrid may include a mixture of materials from the screen element and the subgrid.
According to an exemplary embodiment of the present invention, there is provided a screen assembly including: a screen element comprising a screen element screening surface having a series of screen apertures; and a subgrid including a plurality of elongated structural members forming a grid framework having grid apertures. The screen element spans at least one of the grid holes and is attached to the top surface of the subgrid. A plurality of individual subgrids are secured together to form a screen assembly having a continuous screen assembly screening surface with a plurality of screen element screening surfaces. The screen element includes generally parallel end portions and generally parallel side edge portions generally perpendicular to the end portions. The screen element also includes a first screen element support member extending between the end portions generally parallel to the side rim portions and a second screen element support member orthogonal to the first screen element support member extending between the side rim portions generally parallel to the end portions. The screen element includes a first series of reinforcement members generally parallel to the side margins and a second series of reinforcement members generally parallel to the end margins. The screen element screening surface includes screen surface elements that form the screen openings. The end portions, the side edge portions, the first and second support members, and the first and second series of reinforcement members structurally stabilize the screen surface elements and the mesh openings. The screen element is a single thermoplastic injection molded part. The screen element includes a plurality of pocket cavities on a bottom surface of the screen element. The subgrid includes a plurality of fusion rods on a top surface of the subgrid. The plurality of fusion rods is configured to mate with the plurality of pockets.
The mesh may be an elongated slot having a width and a length, the width of the mesh between the inner surfaces of each of the screen surface elements being approximately about 43 microns to about 1000 microns. The height of the plurality of fusion bars may be slightly greater than the depth of the plurality of pocket cavities. The height of the plurality of fusion bars may be about 0.056 inches. The depth of the plurality of pockets may be about 0.050 inches. The width of each pocket of the plurality of pockets may be slightly greater than the width of each of the plurality of fusion bars. The plurality of fusion rods may be configured such that, upon melting, a portion of the plurality of fusion rods fills a width of the plurality of pocket cavities. The material of the screen element may be fused with the material of the subgrid. The screen member may be configured to allow the laser to pass through the screen member and contact the plurality of fusion rods. The laser may melt a plurality of fusion rods to fuse the screen element to the subgrid.
The subgrid may be a single thermoplastic injection molded part. The screen element may comprise a thermoplastic polyurethane material. The thermoplastic polyurethane may be at least one of a polyether-based thermoplastic polyurethane and a polyester-based thermoplastic polyurethane. The subgrid may include a nylon material. The fusion rod may include at least one of carbon and a graphite material. The subgrid may include a screen element positioning device configured to be positioned over the subgrid. The screen element may comprise a plurality of tapered counter-bores located along the side edges on the top surface of the screen element and end portions between the locating holes of the locating means. The fusion rod and the pocket may be different materials.
The grid frame may include first and second grid frames forming first and second grid apertures, and the screen elements include first and second screen elements. The subgrid may include a ridge portion and a base portion, and the first and second grid frames include first and second angled faces that reach a peak at the ridge portion and extend from the peak portion down to the base portion, wherein the first and second screen elements span the first and second angled faces, respectively. The screen assembly may include a secondary support frame spanning at least a portion of each grid aperture.
According to an exemplary embodiment of the present invention, a screen assembly is provided, comprising a screen element and a subgrid comprising a screen element screening surface having a series of screen openings and a plurality of pocket cavities on a bottom surface of the screen element; the subgrid includes a plurality of elongated structural members forming a grid framework with grid holes and a plurality of fusion rods located on a top surface of the subgrid. The screen element spans the at least one grid aperture and is secured to the top surface of the subgrid by fusing the plurality of fusion rods to the plurality of cavity pockets. The plurality of subgrids are secured together to form a screen assembly having a continuous screen assembly screening surface comprised of a plurality of screen element screening surfaces. The screen element is a single thermoplastic injection molded part. The screen member is configured to allow the laser light to pass through the screen member and contact the plurality of fusion rods.
The screen openings may be elongated slots having a width and a length, with the width of the screen openings being approximately 43 microns to approximately 1000 microns between inner surfaces of each screen surface element. The screen openings may be elongated slots having a width and a length, with the width of the screen openings being approximately 70 microns to approximately 180 microns between inner surfaces of each screen surface element. The screen openings may be elongated slots having a width and a length, with the width of the screen openings being approximately 43 microns to approximately 106 microns between inner surfaces of each screen surface element. The mesh openings may be elongated slots having a width and a length, the width being about 0.044 mm to about 4 mm and the length being about 0.088 mm to about 60 mm.
The subgrid may include generally parallel triangular end pieces, a triangular middle piece generally parallel to the triangular end pieces, first and second intermediate supports generally perpendicular to the triangular end pieces and extending between the triangular end pieces, first and second base supports generally perpendicular to the triangular end pieces and extending between the triangular end pieces and a central spine generally perpendicular to the triangular end pieces and extending between the triangular end pieces, the first rim of the triangular end pieces, the triangular middle piece, the first intermediate support, the first base support, and the central spine forming a first top surface of the subgrid having the first series of grid holes, the second rim of the triangular end pieces, the triangular middle piece, the second intermediate support, the second base support, and the central spine forming a second top surface of the subgrid having the second series of grid holes, the first top surface sloping from the central spine to the first base support, the second top surface slopes from the central ridge to the second base support. The first and second screen elements may span the first and second series of grid apertures, respectively.
In an exemplary embodiment of the invention, a method of manufacturing a screen assembly is provided, including laser welding a screen element of a first material to a sub-grid of a second material; and attaching a plurality of subgrids together to form a screen assembly. The first material and the second material are different materials. The first material and the second material are welded together at the laser weld location.
The screen assembly may have a first adhesive means on the bottom surface of the screen element and the subgrid has a second adhesive means on the top surface of the subgrid. The first adhesive means may be a plurality of pocket cavities and the second adhesive means may be a plurality of fusion bars. The plurality of pockets may be configured to mate with a plurality of fusion rods.
A method for manufacturing a screen assembly may include positioning a screen element on a subgrid through positioning holes in the screen element and positioning extensions on a top surface of the subgrid. A method for making a screen assembly may include passing a laser through a screen element into contact with a plurality of fusion rods. A method for making a screen assembly may include melting a portion of a plurality of fusion bars with the laser. A method for making a screen assembly may include melting a portion of a first material with one of laser generated heat and heat conducted from melted portions of a plurality of fusion bars. A method for making a screen assembly may include removing a laser, mixing a melted portion of a first material and a melted portion of a fusion rod and returning to a solid state.
Example embodiments of the present disclosure are described in more detail below with reference to the accompanying drawings.
Drawings
Figure 1 is an isometric view of a screen assembly according to an exemplary embodiment of the present invention.
Figure 1A is an enlarged exploded view of the screen assembly shown in figure 1.
Figure 1B is a bottom isometric view of the screen assembly shown in figure 1.
Fig. 2 is a top isometric view of a screen element according to an exemplary embodiment of the present invention.
Fig. 2A is a top view of the screen element shown in fig. 2.
Fig. 2B is a bottom isometric view of the screen element shown in fig. 2.
Fig. 2C is a bottom view of the screen element shown in fig. 2.
Figure 2D is an enlarged exploded view of the screen element shown in figure 2.
Fig. 3 is a top isometric view of an end terminal grid according to an exemplary embodiment of the present invention.
Fig. 3A is a bottom isometric view of the end terminal grid shown in fig. 3.
FIG. 4 is a top isometric view of a central subgrid in accordance with an exemplary embodiment of the present invention.
Fig. 4A is a bottom isometric view of the central subgrid shown in fig. 4.
Fig. 5 is a top isometric view of an adhesive strip according to an exemplary embodiment of the invention.
Fig. 5A is a bottom isometric view of the adhesive strip shown in fig. 5.
FIG. 6 is an isometric view of a screen subassembly according to an exemplary embodiment of the present invention.
Fig. 6A is an exploded view of the subassembly shown in fig. 6.
Figure 7 is a top view of the screen assembly shown in figure 1.
Figure 7A is an enlarged cross-section of the screen assembly a-a cross-section shown in figure 7.
Fig. 8 is a top isometric view of a screen assembly partially covered with a screen element in accordance with an exemplary embodiment of the present invention.
Figure 9 is an isometric exploded view of the screen assembly shown in figure 1.
Fig. 10 is an isometric exploded view of an end terminal grid showing a screen element prior to attachment to the end terminal grid in accordance with an exemplary embodiment of the present invention.
Fig. 10A is an isometric view of the terminal subgrid shown in fig. 10 having a screen element attached to the subgrid.
Fig. 10B is a top view of the end terminal grid shown in fig. 10A.
Fig. 10C is a cross-section of the end terminal grid B-B section shown in fig. 10A.
Fig. 11 is an isometric exploded view of a center subgrid showing a screen element prior to attachment to the center subgrid, according to an exemplary embodiment of the invention.
Fig. 11A is an isometric view of the central subgrid shown in fig. 11 with a screen element attached to the subgrid.
Figure 12 is an isometric view of a vibratory screening machine having a screen assembly with a concave screening surface mounted thereon according to an exemplary embodiment of the present invention.
Figure 12A is an enlarged isometric view of the discharge end of the vibratory screen machine shown in figure 12.
Figure 12B is a front view of the vibratory screening machine shown in figure 12.
Figure 13 is an isometric view of a vibratory screening machine with a single screening surface having a screen assembly with a concave screening surface mounted thereon according to an exemplary embodiment of the present invention.
Figure 13A is a front view of the vibratory screening machine shown in figure 13.
Figure 14 is a front view of a vibratory screening machine having two separate concave screening surfaces with a pre-manufactured screen assembly installed thereon according to an exemplary embodiment of the present disclosure.
Figure 15 is a front view of a vibratory screening machine having a single screening surface with a prefabricated screen assembly installed thereon according to an exemplary embodiment of the present disclosure.
Fig. 16 is an isometric view of an end support frame subassembly according to an exemplary embodiment of the present invention.
Fig. 16A is an isometric exploded view of the end support frame subassembly shown in fig. 16.
FIG. 17 is an isometric view of a center support frame subassembly according to an exemplary embodiment of the present invention.
Fig. 17A is an isometric exploded view of the center support frame subassembly shown in fig. 17.
Figure 18 is an isometric exploded view of a screen assembly according to an exemplary embodiment of the present invention.
Figure 19 is a top isometric view of a flat screen assembly according to an exemplary embodiment of the present invention.
FIG. 20 is a top isometric view of a male screen assembly according to an exemplary embodiment of the present invention.
Fig. 21 is an isometric view of a screen assembly having a tapered (pyramidal) subgrid in accordance with an exemplary embodiment of the invention.
Figure 21A is an enlarged view of portion D of the screen assembly shown in figure 21.
Fig. 22 is a top isometric view of a pyramidal end terminal grid in accordance with an exemplary embodiment of the present invention.
Fig. 22A is a bottom isometric view of the pyramidal end terminal grid shown in fig. 22.
FIG. 23 is a top isometric view of a pyramidal central sub-grid in accordance with an exemplary embodiment of the present invention.
Fig. 23A is a bottom isometric view of the pyramidal central subgrid shown in fig. 23.
FIG. 24 is an isometric view of a pyramidal subassembly, according to an exemplary embodiment of the present invention.
Fig. 24A is an isometric exploded view of the pyramidal subassembly shown in fig. 24.
Fig. 24B is an isometric exploded view of a pyramidal terminal grid showing a screen element prior to attachment to the pyramidal terminal grid.
Fig. 24C is an isometric view of the pyramidal end terminal grid of fig. 24B having a screen member attached thereto.
Fig. 24D is an isometric exploded view of a tapered central subgrid according to an exemplary embodiment of the invention, showing a screen element attached prior to the tapered central subgrid.
Fig. 24E is an isometric view of the pyramidal central subgrid shown in fig. 24D having screen elements attached thereto.
Fig. 25 is a top view of a screen assembly having pyramidal subgrids according to an exemplary embodiment of the invention.
Figure 25A is a cross-sectional view of a portion C-C of the screen assembly shown in figure 25.
Fig. 25B is an enlarged view of the portion C-C shown in fig. 25A.
Figure 26 is an isometric exploded view of a screen assembly having pyramidal and flat subassemblies, according to an exemplary embodiment of the invention.
Figure 27 is an isometric view of a vibratory screen machine with two screening surfaces having an assembly with a concave screening surface assembly mounted thereon, wherein the screen assembly includes a pyramidal and flat subassembly, according to an exemplary embodiment of the present invention.
Fig. 28 is a top isometric view of a screen assembly having pyramidal and planar subgrids, but without screen elements, according to an exemplary embodiment of the invention.
Fig. 29 is a top isometric view of the screen assembly of fig. 28 with the subgrid portions covered by the screen elements.
Figure 30 is a front view of a vibratory screening machine with two screening surfaces having screening surfaces with concave screening surface assemblies mounted thereon, wherein the screen assemblies include pyramids and flat subgrids, according to an exemplary embodiment of the present invention.
Figure 31 is a front view of a vibratory screening machine having a single screen surface with an assembly having a concave screening surface mounted thereon, wherein the screen assembly includes pyramids and flat subgrids, according to an exemplary embodiment of the present invention.
Figure 32 is a front view of a vibratory screening machine with two screening surfaces having a pre-manufactured screen assembly with flat screening surfaces mounted thereon, where the screen assembly includes pyramids and flat subgrids, according to an exemplary embodiment of the present invention.
Figure 33 is a front view of a vibratory screening machine with a single screening surface having a pre-manufactured screen assembly with a flat screening surface mounted thereon, where the screen assembly includes pyramids and flat subgrids, according to an exemplary embodiment of the present invention.
Fig. 34 is an isometric view of the end terminal grid of fig. 3 having a single screen element partially attached thereto, according to an exemplary embodiment of the invention.
Fig. 35 is an enlarged view of the broken portion E of the terminal subgrid shown in fig. 34.
Fig. 36 is an isometric view of a screen assembly having a tapered subgrid positioned in a portion of the screen assembly according to an exemplary embodiment of the invention.
Figure 37 is a flow chart of a screen assembly manufacturing process according to an exemplary embodiment of the present invention.
Figure 38 is a flow chart of a screen assembly manufacturing process according to an exemplary embodiment of the present invention.
Figure 39 is an isometric view of a vibratory screening machine having a single screen assembly with a flat screening surface mounted thereon with a portion of the screen assembly shown cut away according to an exemplary embodiment of the present invention.
FIG. 40 is an isometric top view of an individual screen element in accordance with an exemplary embodiment of the present invention.
Fig. 40A is an isometric top view of a screen element cone according to an exemplary embodiment of the invention.
Fig. 40B is an isometric top view of the four screen element cones shown in fig. 40A.
Fig. 40C is an isometric top view of an inverted screen element cone according to an exemplary embodiment of the invention.
Fig. 40D is a front view of the screen element shown in fig. 40C.
Fig. 40E is an isometric top view of a screen element structure according to an example embodiment of the invention.
Fig. 40F is a front view of the screen element construction shown in fig. 40E.
Fig. 41-43 are cross-sectional front sectional views of screen elements according to exemplary embodiments of the present invention.
FIG. 44 is an isometric top view of a prescreen structure having prescreen assemblies according to an example embodiment of the invention.
Figure 44A is an isometric top view of the prescreen assembly shown in figure 44 according to an example embodiment of the invention.
Fig. 45 is a top view of a screen element positioned over a subgrid portion according to an exemplary embodiment of the invention.
Fig. 45A is a cross-sectional view, taken across section a-a, showing the screen element above the subgrid portion of fig. 45. Fig. 45B is a side view of the cross-section a-a of the sub-grid section and screen element shown in fig. 45 prior to attaching the screen element to the sub-grid in accordance with an exemplary embodiment of the present invention.
Fig. 45C is an enlarged view of a portion a shown in fig. 45B.
Fig. 45D is a side view of the cross-section a-a of the sub-grid section and screen element shown in fig. 45 after attachment of the screen element to the sub-grid in accordance with an exemplary embodiment of the present invention.
Fig. 45E is an enlarged view of the portion B shown in fig. 45D.
Fig. 46 is a cross-sectional side view of a portion of a screen element and a portion of a subgrid in accordance with an exemplary embodiment of the present invention.
Figure 47 is a top isometric view of a portion of a screen assembly according to an exemplary embodiment of the present invention.
Fig. 48 is an isometric top view of a screen element according to an exemplary embodiment of the invention.
Fig. 48A is a top view of the screen element shown in fig. 48.
Fig. 48B is a bottom isometric view of the screen element shown in fig. 48.
Fig. 48C is a bottom view of the screen element shown in fig. 48.
Fig. 49 is a top isometric view of a grid of end terminals according to an exemplary embodiment of the present invention.
Fig. 49A is a bottom isometric view of the end terminal grid shown in fig. 49.
FIG. 50 is a top isometric view of a central subgrid according to an exemplary embodiment of the invention.
FIG. 50A is a bottom isometric view of the central subgrid shown in FIG. 50.
Fig. 51 is an isometric exploded view of a terminal grid according to an exemplary embodiment of the invention, showing a screen element prior to attachment to the terminal grid.
FIG. 51A is an isometric view of the end terminal grid shown in FIG. 51 with a screen member attached thereto.
Fig. 52 is an isometric exploded view of a center subgrid showing a screen element prior to attachment to the center subgrid, according to an exemplary embodiment of the invention.
Fig. 52A is an isometric view of the central subgrid shown in fig. 52 having a screen element attached thereto.
Fig. 53 is a top isometric view of a pyramidal end terminal grid in accordance with an exemplary embodiment of the present invention.
Fig. 53A is a bottom isometric view of the pyramidal end terminal grid of fig. 53.
FIG. 54 is a top isometric view of a tapered central subgrid according to an exemplary embodiment of the invention.
Fig. 54A is a bottom isometric view of the pyramidal central subgrid shown in fig. 54.
Fig. 55 is an isometric exploded view of a pyramidal terminal grid showing a screen element attached prior to the pyramidal terminal grid, according to an exemplary embodiment of the present invention.
Fig. 55A is an isometric view of the pyramidal end terminal grid with screen elements shown in fig. 55.
Fig. 56 is an isometric exploded view of a pyramidal center subgrid showing a screen element attached before the pyramidal center subgrid, according to an exemplary embodiment of the invention.
Fig. 56A is an isometric view of the pyramidal central subgrid shown in fig. 56 having a screen element attached thereto.
Fig. 57 is an isometric view of the end terminal grid of fig. 50 with a single screen member partially attached thereto, in accordance with an exemplary embodiment of the present invention.
Fig. 57A is an enlarged view of a portion a of the terminal subgrid shown in fig. 57.
Fig. 58 is a top isometric view of a portion of a screen assembly according to an exemplary embodiment.
Fig. 59 is a top isometric view of a grid of end terminals according to an example embodiment.
Fig. 59A is a bottom isometric view of the end terminal grid shown in fig. 59.
FIG. 60 is a top isometric view of a central subgrid in accordance with an exemplary embodiment.
Fig. 60A is a bottom isometric view of the central subgrid shown in fig. 60.
Fig. 61 is an isometric exploded view of a terminal grid showing a screen element prior to attachment to the terminal grid according to an exemplary embodiment.
Fig. 61A is an isometric view of the end terminal grid of fig. 61 having a screen element attached thereto, according to an exemplary embodiment.
Fig. 62 is an isometric exploded view of a center subgrid showing a screen element prior to attachment to the center subgrid, according to an example embodiment.
Fig. 62A is an isometric view of the central subgrid shown in fig. 62 with a screen element attached thereto in accordance with an exemplary embodiment.
Fig. 63 is a top isometric view of a pyramidal end terminal grid in accordance with an exemplary embodiment.
Fig. 63A is a bottom isometric view of the pyramidal end terminal grid shown in fig. 63.
FIG. 63B illustrates an isometric view of the
FIG. 63C illustrates an isometric view of the
FIG. 63D illustrates an isometric view of
Fig. 64 is a top isometric view of a grid of end terminals according to an example embodiment.
Fig. 64A is a bottom isometric view of the end terminal grid shown in fig. 64.
FIG. 65 is a top isometric view of a central subgrid in accordance with an exemplary embodiment.
FIG. 65A is a bottom isometric view of the central subgrid shown in FIG. 65.
Fig. 66 is an isometric top view of a screen element according to an exemplary embodiment of the invention.
Fig. 66A is a top view of the screen element shown in fig. 66.
Fig. 66B is a bottom isometric view of the screen element shown in fig. 66.
Fig. 66C is a bottom view of the screen element shown in fig. 66.
Fig. 67 is an axial side exploded view of a terminal grid showing a screen element prior to attachment to the terminal grid according to an exemplary embodiment.
Fig. 67A is an isometric view of the end terminal grid shown in fig. 67 having a screen element attached thereto, according to an exemplary embodiment.
Fig. 68 is an isometric exploded view of a center subgrid showing a screen element prior to attachment to the center subgrid, according to an example embodiment.
Fig. 68A is an isometric view of the central subgrid shown in fig. 68 having screen elements attached thereto in accordance with an exemplary embodiment.
Fig. 69 is an isometric view of a screen assembly having a pyramidal subgrid in accordance with an exemplary embodiment of the present invention.
Figure 69A is an enlarged view of portion D of the screen assembly shown in figure 69.
Fig. 70 is a reproduction of fig. 66C showing a bottom view of the screen element for comparison with the screen element of fig. 70A.
Fig. 70A is a bottom view of a screen element having smaller features than the screen elements of fig. 70 and 66.
Fig. 71 is a reproduction of fig. 65 showing a top isometric view of a center sub-grid for comparison with the center sub-grid of fig. 71A.
FIG. 71A is a side isometric view of a central subgrid according to an embodiment.
Fig. 71B is an enlarged view of region "a" of fig. 71A, according to an embodiment.
Fig. 71C is a top view of the center subgrid of fig. 71A, according to an embodiment.
Fig. 71D is a side view of the center subgrid of fig. 71A, according to an embodiment.
Figure 71E illustrates a comparison of support features of a screen element and a terminal grid, according to an embodiment.
Fig. 71F illustrates a comparison of support features of additional screen elements with additional end subgrids, according to an embodiment.
Fig. 72 shows a pyramidal end terminal grid similar to the pyramidal end terminal grid shown in fig. 63, for comparison with the pyramidal end terminal grid of fig. 72A.
Fig. 72A shows a pyramidal end terminal grid having a higher linear density of structural features than 72, according to an embodiment.
Figure 72B illustrates a contrast feature of a screen element to a support feature of a pyramidal end terminal grid, according to an embodiment.
Fig. 72C illustrates a comparison feature of a further screen element to a support feature of a further pyramid-shaped end terminal grid, in accordance with an embodiment.
FIG. 73 illustrates a top view of a screen element, previously illustrated in FIGS. 70A, 71F, and 72C, wherein a first cross-sectional direction A-A and a second cross-sectional direction C-C are defined, in accordance with an embodiment.
FIG. 73A illustrates a first cross-section defined by the first cross-sectional direction A-A shown in FIG. 73, in accordance with an embodiment.
Fig. 73B illustrates an enlarged view of the first cross-section illustrated in fig. 73A, in accordance with an embodiment.
Fig. 73C illustrates a second cross-section of the screen element of fig. 73 defined by a second cross-sectional direction C-C of fig. 73, in accordance with an embodiment.
Fig. 73D illustrates an enlarged view of the second cross-section illustrated in fig. 73C, in accordance with an embodiment.
Fig. 74 illustrates a top view of a center screen subassembly similar to the center screen subassembly of fig. 68A, where a cross-sectional direction a-a is defined, according to an embodiment.
Fig. 74A illustrates a side view of the center screen subassembly of fig. 74, according to an embodiment.
FIG. 74B illustrates a cross-section defined by cross-sectional direction A-A of FIG. 74, in accordance with an embodiment.
Fig. 74C illustrates a first enlarged view of a first portion of the cross-section of the center screen subassembly of fig. 74B, in accordance with an embodiment.
Fig. 74D illustrates a second enlarged view of a second portion of the cross-section of the center screen subassembly of fig. 74C, in accordance with an embodiment.
Fig. 75 illustrates a screen subassembly that has been attached to a rectangular area formed by a grid frame formed by first and second pluralities of rails, according to an embodiment.
Fig. 76 illustrates a screen element directly attached to a plate structure without first attaching the screen element to a subgrid, in accordance with an embodiment.
Fig. 76A shows a screen element configured to be directly attached to a perforated plate, in accordance with an embodiment.
Fig. 76B shows a screen element configured to be directly attached to a corrugated perforated plate, in accordance with an embodiment.
Fig. 76C illustrates a frame having a pocket to receive a screen element, according to an embodiment.
FIG. 77A illustrates an exemplary fusion rod that can be used as a positioning member, according to embodiments.
Fig. 77B illustrates an exemplary pocket that can serve as a locating hole, according to an embodiment.
FIG. 77C shows the fusion rod of FIG. 77A aligned with the pocket of FIG. 77B.
Detailed Description
In some of the drawings, like reference numerals represent like parts.
Embodiments of the present invention provide a screen assembly that includes an injection molded screen element mated with a subgrid. The plurality of subgrids are fixedly secured to one another to form a vibratory screen assembly having a continuous screening surface and configured for use on a vibratory screening machine. The entire screen assembly structure is able to withstand severe loading conditions during installation and operation on a vibratory screening machine. Injection molded screen elements provide a number of benefits in screen assembly manufacturing and vibratory screening applications. In a particular embodiment of the invention, the screen element is injection molded using a thermoplastic material. In some embodiments of the invention, the screen element may have first attachment means configured to mate with second attachment means on the subgrid. The first and second attachment means may comprise different materials and may be configured such that the screen element may be welded to the subgrid via laser welding. The first adhesive means may be a plurality of pockets and the second adhesive means may be a plurality of fusion bars, the fusion bars being configured to melt when subjected to a laser. The screen element may comprise a thermoplastic polyurethane, which may be polyester-based or polyether-based. Embodiments of the invention include a screen member secured to a subgrid by separating a hardened mixture of materials. Embodiments of the invention include methods of making a screen assembly by laser welding a screen element to a subgrid and joining a plurality of subgrids together to form a screen assembly.
Embodiments of the present invention provide an injection molded screen assembly having physical dimensions and configurations for making vibratory screen assemblies and for vibratory screening applications. Several important considerations have been taken into account when configuring a single screen element. The screen assembly provides: having an optimum size (a very small structure large enough to effectively assemble the complete screen assembly structure while being small enough to form a mesh by injection molding (micromold in some embodiments) while avoiding freezing (i.e., hardening of the material in the mold before the mold is completely filled)); having an optimal open screening area (the structure forming the apertures and supporting apertures has a minimum size to increase the overall open area for screening while, in some embodiments, maintaining very small screen openings to properly separate the material to a specified standard); the product has durability and strength, and can work in various temperature ranges; chemical resistance; the structure is stable; the screen assembly has high universality in the manufacturing process of the screen assembly; and may be configured according to a customizable configuration for a particular application.
Embodiments of the present invention provide screen assemblies that are manufactured using extremely precise injection molding. The larger the screen element, the easier it is to assemble a complete vibratory screen assembly. In short, the fewer components that need to be combined, the easier the system is to combine. However, the larger the screen element, the more difficult it is to injection mold very small structures, i.e. structures forming the screening openings. It is important to reduce the size of the structure forming the screen openings to maximize the number of screen openings on a single screen element to optimize the open screening area of the screen element and thus the overall screen assembly. In particular embodiments, the screen elements are large enough (e.g., one inch by one inch, one inch by two inches, two inches by three inches, etc.) so that they can be assembled into a complete screen assembly screening surface (e.g., three feet by two feet, three feet by four feet, etc.). The relatively "small dimensions" (e.g., one inch by one inch, one inch by two inches, two inches by three inches, etc.) are quite large when micromolding very small structural members (e.g., as small as 43 microns). The larger the size of the unitary screen assembly, the smaller the size of the individual structural members forming the screening openings, and the more susceptible to errors such as freezing during the injection molding process. Accordingly, the size of the screen element must be suitable for the manufacture of the screen assembly, while being small enough to eliminate freezing problems during micromolding. The size of the screen elements may vary depending on the injected material, the size of the desired screen openings and the desired overall open screening area.
Open screening area is an important feature of vibratory screen assemblies. The average available open screening area of a conventional 100-to 200-mesh wire screen assembly (i.e., given the structural steel of the support member and the bonding material) may be in the range of 16%, particular embodiments of the present invention (e.g., screen assemblies having the structure herein and having 100-to 200-mesh openings) provide screen assemblies having similar actual open screening areas in the same range, whereas conventional screens plug faster in the field, resulting in a very rapid reduction in actual open screening area. Will not be subject to large scale plugging (thereby maintaining a relatively constant actual open screening area) and will rarely fail. Indeed, screen assemblies according to embodiments of the present invention have an extremely long life and may last for a long period of time under heavy loads. The screen assemblies according to the present invention have been tested under stringent conditions for months without failure or plugging, whereas conventional wire screen assemblies have been tested under the same conditions for plugging and failure in days. As discussed more fully herein, conventional thermoset assemblies cannot be used in such applications.
In an embodiment of the invention, a thermoplastic injection mold screen member is used. Thermoset polymers generally comprise a liquid material that chemically reacts and solidifies at temperature, and in contrast to thermoset polymers, thermoplastics are generally simpler to use and can be provided by melting a homogeneous material (usually in the form of solid spheres) and then injection molding the molten material. The physical characteristics of thermoplastics are not only optimal for vibratory screening applications, but are also easier to manufacture using thermoplastic liquids, particularly when micromolded parts are described herein. The use of thermoplastic materials in the present invention provides excellent flexural and bending fatigue strength and is desirable for intermittent or continuous heavy load components that are subjected to the vibratory screens used on vibratory screening machines. Because the vibratory screening machine is moving, the low coefficient of friction of the thermoplastic injection molding material provides the best wear characteristics. Indeed, some thermoplastics have better abrasion resistance than many metals. Furthermore, the use of thermoplastics as described herein provides the best material for making the "snap" due to the flexible and elongated nature of the thermoplastics. The use of thermoplastics in embodiments of the present invention also provides stress crack resistance, aging resistance, and extreme weathering resistance. The deformation temperature of the thermoplastic is in the range of 200 ℃ F. With the addition of the glass fiber, it will increase to about 250F to about 300F and even higher, and the stiffness (as measured by flexural modulus) will increase from about 400000PSI to over about 1000000 PSI. These properties are desirable when using vibratory screens in vibratory screening machines under the harsh conditions encountered in the field.
Embodiments of the present invention may incorporate various materials into the subgrid unit and/or the screen element depending on the properties desired for the embodiment. Thermoplastic Polyurethane (TPU) may be integrated into embodiments of the present invention (e.g., screen elements) to provide resiliency, transparency, and oil, grease, and wear resistance properties. TPU also has a relatively high shear strength. These characteristics of TPU are beneficial when applied to embodiments of the invention which are subject to high vibration forces, abrasives and high load requirements. Different types of TPU may be incorporated into the examples depending on the material being screened. For example, polyester-based TPUs can be incorporated into screen assemblies for oil and/or gas screening because the esters provide excellent abrasion resistance, oil resistance, mechanical integrity, chemical resistance, and adhesion. Hydrolysis resistance, a characteristic of ether-based TPUs, is important in mining applications, and polyether-based TPUs can be employed. Terephthalocyanate (PPDI) may be incorporated into embodiments of the present invention. PPDI can provide high performance characteristics in a variety of screening applications. The materials of embodiments of the present invention may be selected or determined based on a variety of factors, including the properties of each material and the costs associated with using the material.
In embodiments of the present disclosure, screen element materials may be selected that have high temperature resistance, chemical resistance, hydrolysis resistance, and/or abrasion resistance. The screen elements may comprise materials, such as TPUs, to provide a clear appearance to the screen elements. A clear screen member may be laser welded through the screen member pieces. The subgrid material may be different from the screen element material. In an embodiment of the invention, the subgrid may be nylon. The subgrids may incorporate carbon or graphite. The different materials between the screen member and the subgrids may be secured together by laser welding, which may provide a stronger attachment force between the screen member and the subgrids than other attachment methods. The stronger attachment forces of the screen elements to the subgrids may improve the performance of the screen assembly when subjected to the high vibratory forces of the vibratory screening machine and the abrasive forces generated on the surfaces of the screen elements during material screening.
Figure 1 illustrates a
Fig. 1A is an enlarged view of a portion of a
Figure 1B shows a bottom view of the
The screen assembly shown in figure 1 is slightly concave, for example, with slight curvature in the bottom and top surfaces of the screen assembly. The
Fig. 2 illustrates a
The
Fig. 2B and 2C show the bottom of the
Fig. 3 and 3A show the
The grid framework is constructed from substantially rigid sub-grids, creating a sturdy and durable grid framework and
The end
Figure 4 shows a
Fig. 5 shows a top view of the
The screening elements, screen assemblies, and components thereof, including the attachment elements/fasteners herein, may include nanomaterials dispersed therein for improved strength, durability, and other benefits associated with the use of particular nanomaterials or different combinations of nanomaterials. Any suitable nanomaterial may be used, including but not limited to nanotubes, nanofibers, and/or elastic nanocomposites. The nanomaterial may be dispersed in different percentages in the screen member and screen assembly and its components depending on the desired properties of the final product. For example, certain percentages may be added to increase the strength of the member or to make the screening surface wear resistant. Using a thermoplastic injection molding material having a nanomaterial dispersed therein can increase strength while using less material. Accordingly, the structural members, including the subgrid frame supports and the screen element support members, may be made smaller, stronger, and/or lighter. Building on a complete screen assembly is particularly beneficial when manufacturing relatively small individual assemblies. Furthermore, rather than making individual sub-grids sandwiched together, a large grid structure with nanomaterials dispersed therein can be made, which is relatively light and strong. Individual screen elements, with or without nanomaterials, may be attached to a single complete grid frame structure. The use of nanomaterials in the screen elements will increase the strength while reducing the weight and size of the elements. This may be particularly useful when the holes of the injection molded screen assembly are extremely small, as the holes are supported by the surrounding material/member. Another benefit of incorporating nanomaterials into screen elements is that the improved screening surface has durability and abrasion resistance. The screening surface tends to wear due to heavy use and exposure to abrasive materials, and the use of thermoplastics and/or thermoplastics with abrasion resistant nanomaterials provides a long lasting screening surface.
Fig. 6 shows a sub-assembly 15 of a row of sub-grid cells. Fig. 6A is an exploded view of the subassembly in fig. 6, showing the various subgrids and the orientation of attachment to each other. The subassembly includes two end
Figure 7 shows the
Fig. 8 is a top isometric view of the screen assembly partially covered by the
Figure 9 is an isometric exploded view of the screen assembly shown in figure 1. The figure shows eleven subassemblies attached to each other through the clips and clip apertures of the subgrid end members of the subgrid units of each subassembly. Each subassembly has two end
Fig. 10 and 10A show the
Fig. 10B is a top view of the end subgrid unit shown in fig. 10A with the
Fig. 11 and 11A show the attachment of a
Figures 12 and 12A
Figure 12B is a front view of the vibratory screening machine shown in figure 12. Figure 12B shows
Figures 13 and 13A illustrate the installation of
Figure 14 is a front view of a
Figure 15 is a front view of a
Fig. 16 shows an end support frame subassembly and fig. 16A shows an exploded view of the end support frame subassembly shown in fig. 16. As shown in fig. 16, the end support frame subassembly, includes 11 end
Figure 17 shows a center support frame assembly and figure 17A shows an exploded view of the center support frame subassembly shown in figure 17. The central support frame assembly shown in figure 17 comprises 11 central
Figure 18 shows an exploded view of a screen assembly having three central support frame subassemblies and two end support frame subassemblies. The support frame subassemblies are secured to one another by
Figure 19 shows another embodiment of the invention in which the
Figure 20 shows another embodiment of the present invention in which the screen assembly 56 is convex. The screen assembly 56 may be flexible such that it may be deformed into a more convex shape, or may be substantially rigid. As shown, the screen assembly 56 has an
In other embodiments of the present invention, a
On the underside of the
The end
The end
Each of the plurality of
Fusing rod 476 (or shortened fusing rod 478) may comprise carbon, graphite, or other material configured to respond to a particular laser wavelength. The fusion rod may be further configured to correspond to a laser for laser welding. The fusion rod may have a particular length to correspond to laser 500. Although shown as elongated protrusions, the fusion rod may take on other shapes and/or designs depending on the requirements of the selected laser. In embodiments having fused rods on the subgrids, the
Laser welding typically focuses a laser beam at a joint or region to change the material from a solid to a liquid, and after the laser beam is removed, the material returns to a solid state. Laser welding is a type of welding that can be performed by conduction or infiltration. Conduction welding relies on the conductive ability of the material being welded to generate heat and melt the material. Two different materials may be laser welded together by laser welding the
The end terminal grid cell 414 (or 14) and the center sub-grid cell 418 (or 18) may include a
Fig. 21 and 21A illustrate a cell containing a pyramidal subgrid according to an alternative embodiment of the present disclosure. A screen assembly with a
Fig. 22 and 22A show a
A pyramidal
FIG. 24 shows a sub-assembly of a row of pyramidal sub-grid cells. Fig. 24A is an exploded view of the subassembly of fig. 24, showing a single pyramidal subgrid and the direction of attachment. The subassembly includes two pyramidal
Fig. 24B and 24C show the
Fig. 24D and 24E illustrate the attachment of the
Fig. 53-56A illustrate distal and central
Fig. 25 is a top view of a
Fig. 26 is an isometric exploded view of a screen assembly having pyramidal sub-grid cells. The figure shows that the 11 sub-assemblies are secured to each other by clips and clip apertures along the sub-grid side members of the sub-grid cells of each sub-assembly. Each flat subassembly has two end terminal grids (14 or 414) and three central sub-grids (18 or 418). Each pyramidal subassembly has two pyramidal end terminal grids (58 or 458) and three pyramidal central sub-grids (60 or 460). The
Figure 27 shows a
Figure 28 shows an isometric view of a screen assembly having a pyramidal subgrid with screen elements unattached. The screen assembly shown in fig. 28 is slightly concave, however, the screen assembly may be more concave, convex, or flat. The screen assembly may be made up of a plurality of subassemblies, which may be any combination of flat and pyramidal subassemblies. As shown, 11 sub-assemblies are included, however, more or fewer sub-assemblies may be included. The screen assembly is shown without the screen elements 16 (or 416). The subgrids may be assembled together before or after the screen elements are attached to the subgrids, or any subgrids with attached screen elements may be combined with subgrids without screen elements. Figure 29 shows the screen assembly of figure 28 with a portion of the screen element included. The pyramidal subassembly includes a pyramidal
Figure 31 shows the installation of a screen assembly 81 in a vibratory screening machine having a single screening surface according to an exemplary embodiment of the present invention. The screen assembly 81 is similar in configuration to screen
Figure 32 is a front view of a
Figure 33 is a front view of a
Fig. 34 is an isometric view of the end terminal grid of fig. 3 having a single screen member partially attached thereto. Fig. 35 is an enlarged view of the broken portion E of the terminal subgrid shown in fig. 34. In fig. 34 and 35, the
Fig. 36 illustrates a slightly concave screen assembly 91 having a pyramidal subgrid incorporated into a portion of the screen assembly 91, according to an exemplary embodiment of the invention. The screening surface of the screen assembly may be substantially flat, concave or convex. The screen assembly 91 may be configured to deflect into a preformed shape under a compressive force. As shown in fig. 36, in the portion of the screen assembly mounted on the vibratory screening machine closest to the influent material, the screen assembly 91 includes a pyramidal subgrid. This section contains pyramidal sub-grids, allowing increased screening surface area and directional material flow. A portion of a screen assembly is mounted proximate to a discharge end of a vibratory screening machine and includes a flat subgrid therein. In the flat portion, an area may be provided where material may dry and/or cake on the screen assembly. Various combinations of flat and pyramidal subgrids may be included in the screen assembly depending on the desired configuration and/or particular screening application. In addition, vibratory screening machines that use multiple screen assemblies may have individual screen assemblies in different configurations for use together in a particular application. For example, screen assembly 91 may be used with other screen assemblies positioned near the discharge end of a vibratory screening machine to agglomerate and/or dry material.
Figure 37 is a flowchart illustrating steps for manufacturing a screen assembly according to an exemplary embodiment of the present invention. As shown in fig. 37, a screen manufacturer may receive screen assembly performance specifications for a screen assembly. The specifications may include at least one of material requirements, open screening area, capacity, and cut points of the screen assembly. The manufacturer may then determine the mesh requirements (shape and size) of the screen element herein. The manufacturer may then determine the configuration of the screen (e.g., size of assembly, shape and configuration of screening surface, etc.). For example, a manufacturer may configure a screen element to be at least one of a planar configuration and a non-planar configuration. The planar configuration may be made up of a central sub-grid (18 or 418) and an end terminal grid (14 or 414). The non-flat structure may include at least a portion of a pyramidal central sub-grid (60 or 460) and/or a pyramidal end terminal grid (58 or 458). The screen element may be injection moulded. The sub-grid elements may also be injection molded, but injection molding is not required. As described herein, the screen elements and subgrids may include nanomaterials dispersed therein. After the screen element and subgrid unit are made, the screen element may be attached to the subgrid unit. The screen elements and subgrids may be attached together using a connecting material having an interior dispersed nanomaterial. The screen element may be attached to the subgrid by laser welding. A plurality of sub-grid elements may be attached together to form a support frame. The central support frame is formed by a central sub-grid and the end support frames are formed by end terminal grids. The pyramidal support frame may be formed from pyramidal sub-grid cells. The support frame may be attached such that the central support frame is located at a central portion of the screen assembly and the end support frame is located at an end of the screen assembly. The adhesive strips may be attached to the screen assembly. Different screening areas may be achieved by varying the number of pyramidal sub-grids incorporated into the screen assembly. Alternatively, the screen assembly may be attached to the subgrid unit after the plurality of subgrids are attached together, or after the plurality of support frames are attached together. Rather than a plurality of individual subgrids attached together to form a single unit, one subgrid structure can be fabricated to conform to the desired screen assembly size. A single screen element may then be attached to one subgrid structure.
Figure 38 shows a flowchart of steps for manufacturing a screen assembly according to an example embodiment of the invention. The thermoplastic screen member may be injection molded. The subgrid may be fabricated such that it is configured to receive the screen element. The screen element may be attached to a subgrid, and a plurality of subgrid assemblies may be attached, forming a screening surface. Alternatively, the subgrids may be attached to one another prior to attachment of the screen elements.
In another exemplary embodiment, a method of screening material is provided that includes attaching a screen assembly to a vibratory screening machine and forming a top screening surface of the screen assembly into a concave shape, wherein the screen assembly includes a screen element including a series of screening openings forming a screening surface of the screen element and including a subgrid of a plurality of elongated structural members forming a screen frame having grid apertures. The screen elements span the grid holes and are secured to the top surface of the subgrids. The plurality of subgrids are secured together to form a screen assembly having a continuous screen assembly screening surface comprised of a plurality of screen element screening surfaces. The screen element is a single thermoplastic injection molded part.
Figure 39 is an isometric view of a vibratory screening machine having a
Fig. 40 is an isometric view of a
Fig. 40A and 40B show a
Fig. 40C and 40D show the
Fig. 40E and 40F illustrate a
Fig. 41-43 illustrate cross-sectional views of exemplary embodiments of thermoplastic injection molded screen element surface structures that may be incorporated into the various embodiments of the present invention discussed herein. The screen elements are not limited to the shapes and configurations herein. Because the screen elements are thermoplastic injection molded, a variety of variations may be readily manufactured and incorporated into the various exemplary embodiments discussed herein.
Figure 44 shows a
Fig. 44A shows an enlarged view of
Figure 58 is a top isometric view of a
In other embodiments, a screen assembly similar to the
Fig. 59 is a top isometric view of
In addition to the
The screen element 416 (see, e.g., fig. 61 and 61A) may be attached to the
Fig. 60 is a top isometric view of the center sub-grid 518, and fig. 60A is a bottom isometric view of the center sub-grid 518 shown in fig. 60. The center sub-grid 518 is an alternative embodiment of the center sub-grid 418 shown in fig. 50 and 50A. The
Similarly, the structural features of the central sub-grid 518 (see, e.g., fig. 60, 60A, 62, and 62A) are similar to the central sub-grid 418 (see, e.g., fig. 50, 50A, 52, and 52A) except for the
The screen element 416 (see, e.g., fig. 62 and 62A) may be attached to the
The clip 142 (see, e.g., fig. 59, 59A, 60A, and 63C) includes an extension member similar to the
The use of the clip 142 (see, e.g., fig. 59, 59A, 60A, and 63C) is similar to the use of the clip 42 (see, e.g., fig. 3, 3A, and related discussion). In this regard, the sub-grid cells (e.g.,
As above, with reference to fig. 3 and 3A, when the clip portion of the
In other embodiments, clips 142 may be configured to form a permanent connection between the subgrids that cannot be broken once the connection is made without breaking one or more of the
Fig. 63 is a top isometric view of pyramidal
Also, the structural features of the pyramidal sub-grid 558 (see, e.g., fig. 63 and 63A) are similar to the pyramidal end terminal grid 458 (see, e.g., fig. 53 and 53A) except for the
Fig. 63B, 63C and 63D compare the structural features of clips 42 (fig. 3 and 3A), 142 (fig. 59-62A) and 242 (fig. 63 and 63A), respectively. FIG. 63B shows an isometric view of the
FIG. 63D shows an isometric view of
The above discussion may be directly generalized in that any structure having a
Fig. 64 is a top isometric view of the
However, in contrast to the
Fig. 65 is a top isometric view of the center sub-grid 818, and fig. 65A is a top isometric view of the center sub-grid 818 shown in fig. 65. The center sub-grid 818 is an alternative embodiment of the center sub-grid 518 shown in fig. 60 and 60A. The
In contrast to the center sub-grid 518, the center sub-grid 818 is as long as the center sub-grid 518 and only half as wide as the center sub-grid 518 (e.g., fig. 65 and 65A as compared to fig. 60 and 60A). In other words, the length of the
As described in more detail below (e.g., with reference to fig. 70-74D), the screen elements (e.g., see fig. 70) have smaller features, such as
In this manner, the screen element provides an optimally sized (extremely small structure large enough to effectively assemble the complete screen assembly structure, yet small enough to allow injection molding (micro-molding in some embodiments) of the screen openings while avoiding freezing (i.e., hardening of the material within the mold before the mold is completely filled)); having an optimal open screening area (the structure forming the apertures and supporting apertures has a minimum size to increase the overall open area for screening while, in some embodiments, maintaining very small screen openings to properly separate the material to a specified standard); the product has durability and strength, and can work in various temperature ranges; chemical resistance; the structure is stable; the screen assembly has high universality in the manufacturing process of the screen assembly; and may be configured according to application-specific custom configurations.
Furthermore, the screen elements, sub-grids, and screen assemblies may have different shapes and sizes as long as the structural support members of the sub-grids are used to support the reinforcement parts of the respective screen elements. Screens, subgrids, and screen assemblies can be designed to withstand high vibratory forces (e.g., accelerations in the range of 3-9G), abrasive materials (e.g., fluids having several percent up to 65% abrasive solids), and high load requirements (e.g., fluids having a specific gravity of up to 3 pounds per gallon). The screen assembly may also be designed to withstand compressive loads of up to 2000-3000 pounds of screen assemblies, as described in U.S. Pat. Nos. 7,578,394 and 9,027,760, the entire disclosures of which are incorporated herein by reference. In addition, the design of the disclosed screen assembly enables the size of the screen apertures to be maintained under conditions of use including the compressive loads, high vibratory forces, and the presence of heavy liquids described above.
Fig. 66, 66A, 66B, and 66C illustrate a
In this example, the screen element 516 (see, e.g., fig. 66-66C) is twice as long as the
The
By way of illustration, for example, in fig. 67 and 67A, the
In contrast to the situation shown in fig. 61, two
Illustratively, for example, in fig. 68 and 68A,
In contrast to the situation in fig. 62 where two
Illustratively, for example, in fig. 69 and 69A, the
Fig. 70 and 70A compare a screen element 516 (see fig. 70) with an alternative embodiment screen element 616 (see fig. 70A) having smaller features than the
The
The
The difference between the screen member 516 (of fig. 70) and the screen 616 (of fig. 70A) is related to the support structure, as follows. The
The
Fig. 71 and 71A compare a center sub-grid cell 818 (of fig. 71) with an alternative embodiment center sub-grid cell 918 (of fig. 71A) having additional structural support features. Additional structural support features of the
The center subgrid 918 may be injection molded of thermoplastic (or other suitably selected material) and may contain similar features to those found in the
Similar to the center sub-grid 818, the center sub-grid 918 has a
Fig. 71B shows an enlarged view of the region "a" of fig. 71A. The view of fig. 71B shows two members of
Fig. 71C shows a top-down view of the center sub-grid 918, and fig. 71D shows a side view of the center sub-grid 918. The center subgrid 918 includes a
Fig. 71E and 71F show the corresponding relationship of the reinforcement members of the
The above discussion of
Fig. 72B shows support members 688 of the support frame of the
Similarly, the pyramidal end terminal grid 658 shown in fig. 71F has support members 688 that are spatially aligned with
The following discussion will provide more detail of the
Fig. 73 shows a top view of a
Fig. 73C illustrates a second cross-section of the
Fig. 74 shows a top-down view of a central screen subassembly formed by attaching
Fig. 74B shows a cross-section of the center screen subassembly of fig. 74, which is defined by cross-sectional directions a-a of fig. 74. Fig. 74B also shows the detail "B" area enlarged in fig. 74C and 74D. The elements of support frames 488 and 558 are also shown. As above, the elements of the support frames 488 and 588 are spatially aligned and provide support for the
Fig. 74C is an enlarged view of a cross-sectional "B" portion of the center screen subassembly of fig. 74B. Fig. 74C shows a detail similar to fig. 10C. In this regard, fig. 74C shows the
Fig. 74D illustrates a cross-sectional view of a plurality of
Table 1 (below) shows the percent open area of a screen assembly including
In this embodiment, the
TABLE 1
Number of meshes
W (inch)
T (inch)
L (inch)
% area of opening
80
0.0071
0.014
0.076
23.3
100
0.0059
0.014
0.076
20.3
120
0.0049
0.014
0.076
17.6
140
0.0041
0.014
0.076
13.4
170
0.0035
0.014
0.076
12.2
200
0.0029
0.014
0.076
10.3
230
0.0025
0.014
0.076
9.1
270
0.0021
0.014
0.076
7.9
325
0.0017
0.014
0.076
6.2
Table 2 (below) shows the percent open area of a screen assembly including
Table 2 shows the effect of reducing the length L of the
TABLE 2
Number of meshes
W (inch)
T (inch)
L (inch)
% area of opening
80
0.0071
0.007
0.046
27.3
100
0.0059
0.007
0.046
25.2
120
0.0049
0.007
0.046
23.1
140
0.0041
0.007
0.046
20.5
170
0.0035
0.007
0.046
18.5
200
0.0029
0.007
0.046
16.5
230
0.0025
0.007
0.046
14.9
270
0.0021
0.007
0.046
12.8
325
0.0017
0.007
0.046
10.1
Table 3 (below) shows the percent open area of a screen assembly including
Table 3 shows that this trend may continue. In the present embodiment, the
TABLE 3
Number of meshes
W (inch)
T (inch)
L (inch)
% area of opening
80
0.0071
0.005
0.032
31.4
100
0.0059
0.005
0.032
29.3
120
0.0049
0.005
0.032
27.0
140
0.0041
0.005
0.032
24.1
170
0.0035
0.005
0.032
22.0
200
0.0029
0.005
0.032
19.7
230
0.0025
0.005
0.032
16.4
270
0.0021
0.005
0.032
14.7
325
0.0017
0.005
0.032
12.1
Table 4 (below) shows the percent open area of a screen assembly including
Table 4 shows that as T and L decrease, the open area percentage further increases. In the present embodiment, the
TABLE 4
Number of meshes
W (inch)
T (inch)
L (inch)
% area of opening
80
0.0071
0.003
0.028
32.2
100
0.0059
0.003
0.028
30.1
120
0.0049
0.003
0.028
27.8
140
0.0041
0.003
0.028
25.2
170
0.0035
0.003
0.028
23.1
200
0.0029
0.003
0.028
20.1
230
0.0025
0.003
0.028
17.2
270
0.0021
0.003
0.028
15.3
325
0.0017
0.003
0.028
13.2
According to embodiments, multiple assemblies may be secured together to form a screen assembly having a desired total screening area. For example, a plurality of subgrids are secured together to form a screen assembly having a screening surface with a total screening area of about 0.4m2To 6.0m2. In various embodiments, a total screening area of 0.41m may be constructed2、0.68m2、0.94m2、3.75m2、4.08m2、4.89m2And 5.44m2OfA screen assembly. In other example embodiments, screen assemblies having nearly any total screening area may be constructed by appropriately selecting the size of the screen subassembly and the total number of molecular screen assemblies.
Figures 75 and 76 illustrate different embodiments of alternative strategies that may be used to combine screen elements to form screen assemblies. For example, FIG. 75 shows a system as including a first 702 and a second 704 plurality of tracks. The first plurality of
Rather than using clips (e.g., the
Fig. 76 shows a further embodiment in which the screen elements may be attached directly to the plate structure 752 without first attaching the screen elements to a subgrid. In this embodiment, a plate 752 having a plurality of windows 753a, 753b, 753c, and 753d can be provided. The window holes 753 a-753 d are formed into a plate structure 752 by removing portions of the plate 752, such that the window holes 753 a-753 d include respective grid frames 754a, 754b, 754c, and 754 d. The grid frames 754a, 754b, 754c, and 754d may serve as structures that may provide support for screen elements that may be attached thereto. Thus, the grid frames 754a, 754b, 754c, and 754d may function in the same manner as the above-described sub-grids of the other embodiments. The windows 753a to 753d are shown as conceptual exemplary embodiments. In other embodiments, plate structure 752 may have more windows that may be closely spaced to form a screen assembly having a large open area as described above with respect to other embodiments.
Fig. 76A shows a
In this embodiment,
Fig. 76B illustrates a screen element configured to be directly attached to a corrugated perforated plate, in accordance with an embodiment. In this example, the
Each of the apertures on the
Fig. 76C shows a
The embodiments of fig. 75 and 76-76C illustrate that many different support structures may be provided for the screen elements in addition to the sub-grid structures as previously described with reference to fig. 3-4A, 10A, 11A, 22A, 23-24D, 34, 35, 49-57A, 59-63A, 64-65A, 67-68A, and 71-72C. The support structure need only provide sufficient mechanical and thermal stability to the screen element. The embodiments of figures 75 and 76A to 76C may also allow for a wider choice of materials to be used in creating the screening elements. In certain embodiments, as described in more detail above, it may be advantageous to attach the screen element to the subgrid structure using laser welding. In this regard, certain subgrid structures (e.g., some of the embodiments shown in fig. 3-4A, 10A, 11A, 22A, 23-24D, 34, 35, 49-57A, 59-63A, 64-65A, 67-68A, and 71-72C) may have material properties to compensate for the material properties of the screen element.
For embodiments in which laser welding is used to attach the screen element to the subgrid structure, the screen element should be optically transparent, while the subgrid structure should have optical properties that absorb electromagnetic radiation. In this way, the laser light can pass through the screen element and can be absorbed by the optically absorbing material of the sub-grid structure. The electromagnetic radiation absorbed by the sub-grid structure generates heat, which locally melts the material of the sub-grid structure. After cooling, a connection is formed between the screen element and the subgrid structure. The need for an optically transparent screen member limits the material composition used to create the screen member. In this regard, transparent glass fibers may be used as the reinforcing filler material. However, other filler materials, such as carbon fibers, should not be used because they are not transparent.
The embodiment of fig. 75-76C may use attachment methods other than laser welding, such as gluing as above. Thus, using an attachment technique that does not rely on laser welding, the limitation that the screen element should be optically transparent is eliminated. In this regard, a wider range of materials may be used to produce the screen elements, such as the carbon fibers mentioned above. Filler materials are generally used to enhance the properties of the material, but the presence of filler materials and other additives tends to reduce the cutting, wear and tear properties of the material. Thus, depending on the support structure, the screen element may require more or less filler material. Thus, the properties of certain materials, such as cut, fray, and tear resistance, may be improved with less filler material required. For example, higher temperatures (e.g., >54 ℃ for mining operations, and >90 ℃ for oil and gas operations) typically require more filler material to increase material strength. However, for cases involving lower temperatures and stronger support structures, less filler material requirements may be required. In this case, the properties of the material, such as cutting, abrasion and tear resistance, can be improved.
In the embodiment shown in fig. 75 through 76C, there are many ways to create screen assemblies using support structures. For example,
Many of the embodiments described above have the locating
However, the presence of locating
Fig. 77A, 77B, and 77C illustrate a new embodiment of eliminating alignment holes (e.g., 424 and 525 in fig. 45A-45E, 46, 48B, 48C, 66B, 66C, and 70A) from a screen element. For example, in fig. 77A, 77B and 77C, the pocket and the fusion bar may be redesigned to function as originally performed by the registration holes and the registration members, respectively, thereby eliminating the need to separate the registration holes in the screen element and the registration members in the subgrid, according to the new embodiment shown. FIG. 77A shows an embodiment fusion rod 544 having acute angles 546a and 546 b. FIG. 77B shows an embodiment cavity bag having first 574a and second 574B approximately flat inner surfaces. The cavity bag 572 is designed to be slightly larger than the fusion bar 544 so that the fusion bar 544 can conform to the shape of the cavity bag 572 when a screen member with the cavity bag 572 is placed over a subgrid with the fusion bar 544, as shown in FIG. 77C.
FIG. 77C shows an embodiment in which pocket 572 serves as a registration hole and fusion bar 544 serves as a registration member. In this regard, acute angles 546a and 546b of fusion rod 572 are in contact with generally planar inner surfaces 574a and 574b, respectively, of cavity bag 572. Fusion rod 544 is sized and shaped to allow fusion rod 544 to be in intimate contact with inner surfaces 546a and 546b of cavity bag 572. With this design, there is little freedom of relative movement between pocket 572 and fusion bar 544. Thus, as shown in fig. 77C, the screen element may be properly aligned on the subgrid by close tolerances in the alignment between the fusion rod 544 and the cavity bag 572. In this regard, the need to separate the positioning member and the positioning hole is eliminated.
Embodiments of the invention described herein, including screen members and screen assemblies, may be configured for use with different vibratory screening machines and portions thereof, including machines designed for dry and wet applications, machines with multi-deck decks and/or multiple screen baskets, and machines with various screen attachment arrangements, such as tensioning mechanisms (under and over mounted), compression mechanisms, flexing mechanisms, magnetic mechanisms, and the like. For example, screen assemblies described herein may be configured to be installed in vibratory screening machines as described in U.S. patent nos. 7,578,394, 5,332,101, 6,669,027, 6,431,366, and 6,820,748. Further, a screen assembly as described herein may include: side portions or adhesive strips of a U-shaped member including a tension member configured to receive an upper mount type, such as described in U.S. patent No. 5,332,101; side portions or adhesive strips including finger receiving apertures configured to receive underlying mounting tension members, such as described in U.S. patent No. 6,669,027; side portions or adhesive strips for compressive loading, for example, as described in U.S. Pat. No. 7,578,394; or may be configured to attach to and be carried on a multi-deck platform machine, such as the machine described in U.S. patent No. 6,431,366. The screen assemblies and/or screen elements may also be configured to include the features described in U.S. patent application No. 12/460,200 (now patent No. 8,443,984), including the guide assembly technology described therein, as well as the precast panel technology. Still further, screen groupings and screen elements may be configured to include pre-screening technologies (e.g., compatible with mounting structures and screening arrangements) such as those described in U.S. patent application No. 12/051,658 (now patent No. 8,439,203), U.S. patent nos. 7,578,394, 5,332,101, 4,882,0544,857,176, 6,669,027, 7,228,971, 6,431,366, and 6,820,748, and U.S. patent application No. 12/460,200 (now patent No. 8,443,984) and U.S. patent application No. 12/051,658 (now patent No. 8,439,203), their related patent families and applications, and patent applications, incorporated herein by reference.
In the foregoing, example embodiments have been described. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the application. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense.
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