EA039521B1 - Injection molded screening apparatuses and methods - Google Patents

Abstract

The invention relates to screening members, screening assemblies, methods for fabricating screening members and assemblies and methods for screening materials for vibratory screening machines that incorporate the use of injection molded materials. The use of injection molded screen elements provides, inter alia, for varying screening surface configurations; fast and relatively simple screen assembly fabrication; and a combination of outstanding screen assembly mechanical and electrical properties, including toughness, wear and chemical resistance. Embodiments of the invention use a thermoplastic injection molded material.

Description

Cross-reference to related applications

This patent application claims priority from U.S. Patent Application No. 15965195, filed April 27, 2018, which in turn claims priority from U.S. Provisional Application No. 62/648771, filed March 27, 2018, and is also a continuation in part of the patent. U.S. Application No. 15/851099, filed December 21, 2017, which is a division of U.S. Patent Application No. 15/201865, filed July 5, 2016, now U.S. Patent No. 9,884,344, which is a continuation of U.S. Patent Application No. 14 /268101, filed May 2, 2014, currently US Patent No. 9409209, which is a partial continuation of US Patent Application No. 13/800826, filed March 13, 2013, which claims the priority of US Provisional Patent Applications No. 61/652039 , filed May 25, 2012, and 61/714882, filed October 17, 2012, the entire contents of which are incorporated herein by reference.

The field of technology to which the invention relates

The present invention generally relates to the screening of materials. More specifically, the present invention relates to screening elements, screening assemblies, methods for manufacturing screening elements and assemblies, and methods for screening materials.

Prior Art

The screening of materials includes the use of vibrating screens. Vibrating screens provide the ability to excite the installed sieve so that the materials placed on the sieve can be separated to the required level. Oversize products are separated from undersize products. Over time, the screens wear out and need to be replaced. For this reason, the sieves are made with the possibility of their replacement.

The replaceable screen assemblies must be securely attached to the vibrating screen and are subjected to high vibrational forces. The replaceable screens can be attached to the vibrating screen by means of tension elements, compression elements or clamping elements.

Replaceable screen assemblies are usually made of metal or thermosetting polymer. The material and configuration of the replaceable screens depends on the screening application. For example, metal screens, due to their relative durability and fine screening capability, are often used for wet screening in the oil and gas industry. However, conventional thermoset screens (eg cast polyurethane screens) are not as durable and will likely not withstand the rigors of such wet screening and are often used for dry screening applications such as the mining industry.

Fabrication of thermosetting polymer screens is relatively complex, time consuming and prone to scrap. Typical thermoset-type polymer screens that are used with vibrating screens are made by combining separate fluids (e.g., polyester, polyether, and hardener) that chemically react and then allow the mixture to cure in the mold over a period of time. When making sieves with fine openings, for example from about 43 to about 100 microns, this process can be extremely complex and time consuming. Indeed, in order to create fine holes in the sieve, the channels in the molds through which the liquid passes must be very small (for example, on the order of 43 microns), and all too often the liquid does not reach all the cavities in the mold. As a result, complex procedures are often applied that require close attention to pressures and temperatures. Since a relatively large (eg, two feet by three feet (-60x90 cm) or more) single sieve is made in the mold, one defect (eg, a hole, i.e., a place that the liquid has not reached) will destroy the entire sieve. Thermoset polymer sieves are typically made by molding the entire sieve assembly as a single large screen element, with the sieve assembly having openings ranging from about 43 to about 4000 microns. The screening surface of conventional thermosetting polymer sieves typically has a uniform flat configuration.

Thermoset polymer screens are relatively flexible and are often attached to the vibrating screen using tension members that pull the side edges of the thermoset polymer screen apart and attach the bottom surface of the thermoset polymer screen to the surface of the shaker screen. To prevent deformation under tension, thermoset polymer assemblies can be molded with aramid fibers that extend in the direction of tension (see, for example, US Pat. No. 4,819,809). If a compressive force were applied to the side edges of typical thermoset polymer screens, they would warp or buckle, thereby rendering the screen surface relatively ineffective.

Unlike thermoset polymer screens, metal screens are rigid and can be compressed or stretched on a vibrating screen. Metal sieve assemblies are often made from a variety of metal elements. The manufacture of metal sieve assemblies usually includes the manufacture of a screening material, often three-layered, from woven wire mesh; manufacturing a perforated metal base plate; and attaching the screening material to the perforated metal base plate. The wire cloth layers may be finely woven with openings ranging from about 30 to about 4000 microns. The entire screening surface of conventional metal assemblies typically has a relatively uniform flat configuration or a relatively uniform corrugated configuration.

Critical to the screening performance of screen assemblies (thermosetting polymer assemblies and metal type assemblies) for vibrating screens are the size of the openings in the screening surface, the structural stability and durability of the screening surface, the structural stability of the entire module, the chemical properties of the module elements, and the ability of the module to operate at various temperatures and environments. The disadvantages of conventional metal assemblies include insufficient structural stability and durability of the screening surface formed by layers of woven wire mesh, clogging (clogging of the screening holes with particles) of the screening surface, the weight of the entire structure, the time and cost associated with the manufacture or purchase of each of the elements, as well as assembly time and cost. Because screen makers often outsource wire cloth and often buy it from weavers or wholesalers, quality control can be extremely difficult and wire cloth often has problems. Defective wire cloth can lead to sieve performance problems, so constant monitoring and control is required.

One of the biggest problems with conventional metal knots is clogging. A new metal screen may initially have a relatively large screening area, but over time, as the screen is exposed to particles and screen hole plugging (i.e. plugging), the screening area, as well as the effectiveness of the screen itself, decline relatively quickly. For example, a 140 mesh screen assembly (having three layers of screen fabric) may have an initial screening area of 20-24%. However, during the operation of the sieve, the screening cross section can decrease by 50% or more.

Conventional metal screen assemblies also lose a large screening area due to their design, which includes adhesives, backing plates, plastic sheets that bind layers of wire cloth together, and so on.

Another major issue with conventional metal screens is screen life. Ordinary metal assemblies usually fail, not from wear, but from metal fatigue. That is, the wires of the woven wire mesh often actually break due to the up and down movements they are subjected to during vibration loading.

The disadvantages of conventional thermoset polymer sieves also include insufficient structural stability and durability. Additional disadvantages include an inability to withstand compression-type loading and an inability to withstand high temperatures (for example, thermoset polymer-type screens typically begin to fail or experience performance problems at temperatures in excess of 130°F (54.4°C), especially screens with fine holes, for example, from about 43 to about 100 microns in size). In addition, as discussed above, their manufacture is complex, time consuming and prone to rejects. In addition, the molds used to make thermoset polymer sieves are expensive and any defect or the slightest damage to them will destroy the entire mold and require replacement, which can lead to costly downtime in the manufacturing process.

Another disadvantage of both conventional metal and thermoset polymer sieves is the limitation of available screen surface configurations. Existing screen surfaces are made with relatively uniform opening sizes throughout the screen and a relatively uniform surface configuration throughout the screen, regardless of whether the screen surface is flat or wavy.

The conventional polymer-type screens referred to in U.S. Provisional Application No. 61/652039 (also referred to therein as conventional polymer screens, existing polymer screens, conventional polymer screens, or simply polymer screens) refer to the conventional thermoset polymer screens disclosed in U.S. Provisional Patent Application No. 61/714882 and conventional thermoset polymer sieves disclosed herein (also referred to herein and in U.S. Provisional Application No. 61/714882 as conventional thermoset polymer sieves, existing thermoset polymer sieves, conventional thermoset polymer sieves, or simply thermoset sieves ). Accordingly, the conventional polymer type screens discussed in U.S. Provisional Application No. 61/652039 are the same conventional thermoset polymer type screens discussed here and in U.S. Provisional Application No. 61/714882 and can be made with extremely small screen openings ( as disclosed herein and in U.S. Provisional Application No. 61/714882) but have all the disadvantages (as disclosed herein and in U.S. Provisional Application No. 61/714882) associated with conventional thermoset polymer sieves, including lack of structural stability and durability, failure to withstand compression-type loads, failure to withstand high temperatures, and complex, time-consuming, defect-prone manufacturing methods.

- 2 039521

There is a need for versatile and improved screening elements, screening assemblies, methods for manufacturing screening elements and assemblies, and methods for screening materials for vibrating screens, which include the use of injection molded materials (for example, thermoplastics) having improved mechanical and chemical properties.

The essence of the invention

The present invention is an improvement over existing screen assemblies and methods for screening and manufacturing screen assemblies and parts thereof. The present invention provides extremely versatile and improved screening elements, screening assemblies, methods for making screening elements and assemblies, and methods for screening materials for vibrating screens, which include the use of injection molded materials having improved properties, including mechanical and chemical properties. In particular embodiments of the present invention, a thermoplastic is used as the injection molded material. The present invention is not limited to thermoplastic injection molding materials, and other materials that have similar mechanical and/or chemical properties may be used in embodiments of the present invention. In embodiments of the present invention, a plurality of injection-molded sieve elements are securely attached to the sub-array structures. The subgrids are bonded together to form a sieve assembly that has a screening surface including a plurality of sieve elements. The use of injection-molded sieve elements with the various embodiments disclosed herein provides, inter alia: variability in screen surface configurations; fast and relatively simple production of sieve units; and the combination of exceptional mechanical, chemical and electrical properties of the sieve assembly, including stiffness, wear resistance and chemical resistance.

Embodiments of the present invention include screen assemblies that are designed to have relatively large screening clearances while having structurally stable small screen openings for fine vibratory screening applications. In embodiments of the present invention, the screen openings are very small (e.g., down to about 43 microns) and the screen elements are quite large (e.g., one inch by one inch (-25.4x25.4 mm), one inch by two inches (-25, 4x50.8 mm), two inches by three inches (-50.8x76.2 mm), etc.) to realize the installation of the entire screening surface of the sieve assembly (for example, two feet by three feet (-60x90 cm), three feet by four feet (-90x120 cm), etc.). Making small screen holes for fine screening requires injection molding of very small structural elements that actually form the screen holes. These structural elements are injection molded to be integral with the sieve element design. It is important to note that the structural elements are small enough (for example, in some cases they may have a screening surface width of the order of approximately 43 microns) to provide an effective total screening area and form part of the entire screen element structure that is large enough (for example, two inches per three inches (-50.8x76.2 mm)) so that it is reasonable to collect a relatively large total screening surface from them (for example, two feet by three feet (-60x90 cm)).

In one of the embodiments of the present invention, the thermoplastic material is subjected to injection molding to obtain screening elements. Thermoplastics have not previously been used in the fabrication of vibrating screens with small openings (e.g., from about 43 to about 1000 µm) because it would be extremely difficult, if not impossible, to injection mold a single relatively large vibrating screen structure having small openings from a thermoplastic. , and obtain the screening area required for competitive performance in vibratory screening applications.

According to one embodiment of the present invention, a screen assembly is provided that: is structurally stable and can be subjected to various loading conditions, including compression, tension, and pressure; can withstand high vibration forces; includes a plurality of injection molded sieve elements which, due to their relatively small size, can be made with extremely small openings (having dimensions of approximately 43 µm); eliminates the need for wire cloth; is easy; recyclable; simple and easy to install; can be made in many different configurations, including different sizes of sieve openings throughout the sieve and various screening surface configurations, for example, various combinations of flat and wavy sections; and can be made from application-specific materials and nanomaterials. In addition, each screen assembly can be custom made for a particular application and can be simply and easily manufactured with various opening sizes and configurations depending on end user requirements. Embodiments of the present disclosure may be applied to a variety of applications, including wet and dry screening applications, and

- 3 039521 can be used in various industries. The present invention is not limited to the oil and gas industry and the mining industry. The disclosed embodiments can also be used in any industry that requires material separation using vibrating screens, including pulp and paper, chemicals, pharmaceuticals, and others.

In one exemplary embodiment of the present invention, a sieve assembly is provided that significantly improves screening of materials using an injection molded thermoplastic sieve element. A plurality of injection molded thermoplastic polymer screen elements are securely attached to the subgrid structures. The subgrids are bonded together to form a sieve assembly that has a screening surface including a plurality of sieve elements. Each sieve element and each sub-array may have different shapes and configurations. Individual injection-molded thermoplastic screen elements provide accurate screening holes that can be approximately 43 microns in size. The screen frame may be substantially rigid and may be resistant to damage or deformation from the significant vibration loads it is subjected to when attached to the vibrating screen. In addition, the subgrids, when assembled to form the entire screen assembly, are strong enough not only to withstand vibration loading, but also for the forces required to attach the screen assembly to the vibrating screen, including heavy compressive loads, tensile loads, and/or or clamping loads. In addition, the openings in the subgrids structurally support the screen elements and transmit vibrations from the vibrating screen to the screen opening elements, thereby optimizing screening performance. The screen elements, sub-grids and/or any other element of the screen assembly may include nanomaterials and/or glass fibers which provide durability and strength in addition to other benefits.

In accordance with one exemplary embodiment of the present invention, a sieve assembly is provided, comprising a sieve element having a screening surface of the sieve element with a group of screening holes, and a subgrid including a plurality of elongated structural elements forming a sieve frame having sieve holes. The sieve element covers at least one of the lattice openings and is attached to the upper surface of the sub-array. A plurality of individual subgrids are bonded together to form a sieve assembly, and the sieve assembly has a continuous sieve assembly screening surface containing a plurality of sieve assembly sieve elements. The sieve element includes substantially parallel end portions and substantially parallel side edge portions substantially perpendicular to the end portions. The sieve element further includes a first sieve element support element and a second sieve element support element orthogonal to the first sieve element support element. The first support element of the sieve element extends between the end portions and is approximately parallel to the side edge portions. The second supporting element of the sieve element extends between the side edge parts and is approximately parallel to the end parts. The sieve element includes a first group of reinforcing elements essentially parallel to the side edge parts and a second group of reinforcing elements essentially parallel to the end parts. The screening surface of the sieve element includes elements of the sieve surface forming screening holes. The end parts, side edge parts, the first and second supporting elements and the first and second groups of reinforcing elements structurally stabilize the elements of the screen surface and the screening holes. The sieve element is made in the form of a single thermoplastic part obtained by injection molding.

Screening holes can be rectangular, square, round and oval or any other shape. The elements of the screen surface can run parallel to the end parts, forming screening holes. The screen surface elements can also extend perpendicular to the end portions to form screening holes. Various combinations of rectangular, square, round and oval (or other shapes) screening holes can be combined and, depending on the shape used, can run parallel and/or perpendicular to the end portions.

The screen surface elements may extend parallel to the end portions and may be elongated elements forming screening holes. The screening holes may be elongated slots having a distance of from about 43 to about 4000 microns between the inner surfaces of adjacent elements of the screen surface. In some embodiments, the screen openings may have a distance of about 70 to about 180 microns between the inside surfaces of adjacent screen surface elements. In other embodiments, the screen openings may have a distance of from about 43 to about 106 microns between the inside surfaces of adjacent screen surface elements. In embodiments of the present invention, the screening holes may have a width and length, wherein the width may be from about 0.043 to about 4 mm, and the length can be from about 0.086 to about

- 4 039521 mm. In some embodiments, the width to length ratio may be from about 1:2 to about 1:1000.

A plurality of sub-grids of different sizes can be combined to provide a screen assembly support structure for the screen elements. Alternatively, one subgrid may be injection molded or otherwise formed from a thermoplastic to form the entire screen assembly support structure for a plurality of individual screen elements.

In embodiments where a plurality of sub-arrays are used, the first sub-array may include a first base element having a first fixing means mating with a second fixing means of the second base element of the second sub-array, the first and second fixing means securing the first and second sub-lattices together. The first locking means may be a latch and the second locking means may be a latch hole, wherein the latch snaps into the latch hole and securely secures the first and second sublattices together.

The first and second sieve element support elements and the sieve element end portions may include a sieve element attachment device configured to mate with the subgrid attachment device. The subgrid fastener may include elongated fasteners, and the screen element fastener may include fastening holes that mate with the elongated fasteners securely attaching the screen element to the subgrid. Part of the elongated fastening element can be made with the possibility of passing through the fastening holes of the sieve element and slightly above the screening surface of the sieve element. The mounting holes may include a tapered bore, or may simply include a non-tapered hole. The portion of the elongated fastener above the screening surface of the sieve element may be melted and may fill the conical channel, securing the screening element to the subgrid. Alternatively, the portion of the elongated fasteners that extends through and above the opening of the screening surface of the sieve element may be melted to form a collar on the screening surface of the sieve element and secure the sieve element to the subgrid.

The elongated structural members may include substantially parallel subarray end members and substantially parallel subarray side members substantially perpendicular to the subarray end members. The elongated structural elements may further include a first sublattice support element and a second sublattice support element orthogonal to the first sublattice support element. The first subarray support element may extend between the end elements of the subarray and may be approximately parallel to the side elements of the subarray. The second support member of the sub-array may extend between the side members of the sub-array and may be approximately parallel to the end members of the sub-array and substantially perpendicular to the edge members of the sub-array.

The lattice frame may include first and second lattice frames forming the first and second lattice openings. The sieve elements may include first and second sieve elements. The sublattice may have a ridge part and a base part. The first and second lattice frames may include first and second sloped surfaces that form a peak on the ridge portion and slope downward from the peak to the base portion. The first and second screen elements may surround the first and second inclined surfaces, respectively.

In accordance with one exemplary embodiment of the present invention, a sieve assembly is provided comprising a sieve element including a screening surface of the sieve element with a group of screening holes and a subgrid including a plurality of elongated structural elements forming a sieve frame having sieve holes. The sieve element covers at least one lattice opening and is attached to the upper surface of the sub-array. A plurality of subgrids are bonded together to form a sieve assembly, wherein the sieve assembly has a continuous screening surface of the sieve assembly consisting of a plurality of screening surfaces of the sieve elements. The sieve element is a single thermoplastic part obtained by injection molding.

The screen element may include substantially parallel end portions and substantially parallel side edge portions substantially perpendicular to the end portions. The sieve element may further include a first sieve element support element and a second sieve element support element orthogonal to the first sieve element support element. The first support element of the sieve element may extend between the end portions and may be approximately parallel to the side edge portions. The second support element of the sieve element may extend between the side edge portions and may be approximately parallel to the end portions. The sieve element may include a first group of reinforcing elements substantially parallel to the side edge portions and a second group of reinforcing elements substantially parallel to the end portions. The sieve element may include elongated sieve surface elements extending parallel to the end portions and forming screening holes. End parts, side edge parts, first and second supporting elements, first and second groups

- 5 039521 reinforcing elements can structurally stabilize the elements of the sieve surface and screening holes.

The first and second groups of reinforcing elements may have a thickness that is less than the thickness of the end parts, side edge parts and the first and second supporting elements of the sieve element. The end portions and side edge portions, as well as the first and second support members of the screen element, may form four rectangular regions. The first group of reinforcing elements and the second group of reinforcing elements may form a plurality of rectangular support grids in each of the four rectangular regions. The screening holes may have a width of from about 43 to about 4000 microns between the inner surfaces of each of the elements of the screening surface. In some embodiments, the screen openings may have a width of from about 70 to about 180 microns between the inner surfaces of each of the elements of the screen surface. In other embodiments, the screen openings may have a width of from about 43 to about 106 microns between the inner surfaces of each of the elements of the screen surface. In embodiments of the present invention, the screen openings may have a width of from about 0.043 to about 4 mm and a length of from about 0.086 to about 43 mm. In some embodiments, the width to length ratio may be from about 1:2 to about 1:1000.

The sieve elements may be flexible.

The end members of the sub-array, the side members of the sub-array, and the first and second supporting members of the sub-array may form eight rectangular lattice openings. The first sieve element may surround four grid holes, and the second sieve element may cover four other holes.

The central part of the screening surface of the screening element may bend slightly under load. The sublattice may be substantially rigid. The subgrid can also be a single injection molded thermoplastic piece. At least one of the end elements of the sub-array and the side elements of the sub-array may include locking means configured to interface with the fixing means of other sub-arrays, while these fixing means may be latches and latch holes that snap into place and securely fasten the sub-arrays together.

The sublattice may include substantially parallel triangular end members, triangular middle members substantially parallel to the triangular end members, first and second mid-posts substantially perpendicular to the triangular end members and extending between the triangular end members, first and second base legs. , essentially perpendicular to the triangular end elements and passing between the triangular end elements, and a Central ridge, essentially perpendicular to the triangular end elements and passing between the triangular end elements. The first edge of the triangular end elements, the triangular middle elements and the first middle support, the first base support and the central ridge may form the first top surface of the sublattice having the first group of lattice holes. The second edge of the triangular end elements, the triangular middle elements and the second middle support, the second base support and the central ridge may form a second upper surface of the sublattice having a second group of lattice holes. The first top surface may slope down from the central ridge to the first base leg, and the second top surface may slope down from the central ridge to the second base leg. The first and second screen elements may surround the first group and the second group of grid holes, respectively. The first edges of the triangular end elements, the triangular middle elements, the first middle support, the first base support, and the central ridge may include a first subgrid attachment device configured to securely mate with the first screen element attachment device of the first screen element. The second edges of the triangular end elements, the triangular middle elements, the second middle support, the second base support, and the central ridge may include a second subgrid attachment device configured to securely mate with the second screen element attachment device of the second screen element. The first and second subgrid fasteners may include elongated fasteners, and the first and second screen element fasteners may include fastening holes that mate with the elongated fasteners, securely attaching the first and second screen elements to the first and second subgrids, respectively. Parts of the elongated fastening elements can pass through the fastening holes of the sieve element and slightly extend above the first and second screening surfaces of the sieve element.

Each of the first and second screen elements may include substantially parallel end portions and substantially parallel side edge portions substantially perpendicular to the end portions. Each of the first and second sieve elements may include a first sieve element support element and a second sieve element support element orthogonal to the first sieve element support element, wherein the first sieve element support element extends between the end portions and is approximately parallel to the side edge parts, the second support element of the sieve element extends between the side edge parts and may be approximately parallel to the end parts. Each of the first and second screen elements may include a first group of reinforcing elements substantially parallel to the side edge portions and a second group of reinforcing elements substantially parallel to the end portions. The first and second sieve elements may include elongated sieve surface elements extending parallel to the end portions and forming screening holes. The end parts, the side edge parts, the first and second supporting elements, the first and second groups of reinforcing elements can structurally stabilize the screen surface elements and the screening holes.

One of the first and second base supports may include locking means that fasten together a plurality of sublattices, which locking means may be latches and latch holes that snap into place and securely fasten the sublattices together.

The sieve assembly may include first, second, third, and fourth sieve elements. The first group of lattice holes may be eight holes formed by the first edge of the triangular end members, the triangular middle members, and the first middle leg, the first base leg, and the central ridge. The second group of lattice holes may be eight holes formed by the second edge of the triangular end elements, the triangular middle elements, the second middle support, the second base support and the central ridge. The first sieve element may surround four grid holes from the first group of grid holes, and the second sieve element may cover four other holes from the first group of grid holes. The third sieve element may surround four of the lattice holes from the second group of lattice openings, and the fourth sieve element may surround four other openings from the second group of lattice openings. The central part of the first, second, third and fourth screening surfaces of the sieve element can be slightly bent under load. The subgrid may be substantially rigid and may be a single injection molded thermoplastic piece.

In accordance with one of the exemplary embodiments of the present invention, the sieve assembly provides for the presence of a sieve element, which includes a screening surface of the sieve element with screening holes, and a subgrid, including a lattice frame with lattice holes. The sieve element covers the lattice openings and is attached to the surface of the sublattice. A plurality of subgrids are fastened together to form a sieve assembly, wherein the sieve assembly has a continuous screening surface of the sieve assembly including a plurality of screening surfaces of the sieve elements. The sieve element is a thermoplastic part obtained by injection molding.

The sieve assembly may also include a first injection molded thermoplastic sieve element and a second injection molded thermoplastic sieve element, wherein the screen frame may include a first and a second screen frame forming a first screen hole and a second screen hole . The sub-array may include a ridge portion and a base portion, wherein the first and second lattice frames include first and second sloped surfaces that form the peak of the ridge portion and extend obliquely downward from the peak to the base portion. The first and second screen elements may surround the first and second inclined surfaces, respectively. The first and second inclined surfaces may include a subgrid attachment device configured to securely mate with the screen element attachment device. The subgrid fastener may include elongated fasteners, and the screen element fastener may include holes that mate with the elongated fasteners, securely attaching the screen elements to the subgrid.

The subgrid may be substantially rigid and may be a single injection molded thermoplastic piece. The base portion section may include first and second fixing means that attach a sublattice to third and fourth fixing means of another sublattice. The first and third locking means may be snaps, and the second and fourth locking means may be snap holes. The latches can snap into the latching holes and securely fasten together a sub-grid and then another sub-grid.

The subgrids may form a concave structure, and the continuous screening surface of the sieve assembly may be concave. The subgrids may form a flat structure, and the continuous screening surface of the sieve assembly may be flat. The subgrids may form a convex structure, and the continuous screening surface of the sieve assembly may be convex.

The sieve assembly can be configured to acquire a predetermined concave shape when it is subjected to a compression force generated by the vibrating screen compression assembly on at least one side member of the vibrating sieve assembly when it is installed in the vibrating screen. The predetermined concave shape can be determined according to the surface shape of the vibrating screen. The sieve assembly may have a mating surface that mates the sieve assembly with the surface

- 7 039521 vibrating screen, and the mating surface may be rubber, metal (eg steel, aluminum, etc.), composite material, plastic material or any other suitable material. The sieve assembly may include a mating surface configured to mate with a mating surface of the vibrating screen such that the sieve assembly is guided into a fixed position on the vibrating screen. The mating surface can be made in the area of at least one sublattice. The mating surface of the sieve assembly may be a recess made in the corner of the sieve assembly, or a recess made approximately in the middle of the side edge of the sieve assembly. The sieve assembly may have an arched surface configured to mate with the concave surface of the vibrating screen. The screen assembly may have a substantially rigid structure that does not substantially buckle when attached to the vibrating screen. The screen assembly may include a mating surface of the screen assembly configured to assume a predetermined concave shape when subjected to a compression force from the vibrating screen element. The mating surface of the sieve assembly may be shaped to mate with the mating surface of the vibrating screen so that the sieve assembly can be guided to a predetermined location on the vibrating screen. The sieve assembly may include a load bar attached to the edge surface of the sieve assembly subgrid. The load bar can be configured to distribute the load over the surface of the sieve assembly. The sieve assembly can be made with the possibility of acquiring a given concave shape when the compressive element of the vibrating screen applies a compression force to the load bar of the sieve assembly. The sieve assembly may have a concave shape and may be made with the possibility of bending and acquiring a given concave shape when a compression force is applied to the vibrating screen element.

The first set of subgrids may form the center nodes of the support frame having the first locking device. The second set of subgrids may form a first support frame end assembly having a second locking device. The third set of subgrids may form a second support frame end assembly having a third locking device. The first, second and third fixing devices may attach the first and second end support frames to the central support nodes. The side edge surface of the first end assembly of the support frame may form the first end of the screen assembly. The side edge surface of the second end assembly of the support frame may form the second end of the screen assembly. The end surface of each of the first and second end assemblies of the support frame and the central assemblies of the support frame may collectively form the first and second side surfaces of the entire sieve assembly. The first and second side surfaces of the screen assembly may be substantially parallel, and the first and second end surfaces of the screen assembly may be substantially parallel and substantially perpendicular to the side surfaces of the screen assembly. The side surfaces of the sieve assembly may include locking means configured to engage with at least one of the connecting bar and the load distribution bar. The sublattices may have side surfaces such that when the individual sublattices are bonded together to form the first and second end nodes of the support frame and the central node of the support frame, each of the first and second end nodes of the support frame and the central node of the support frame acquires a concave shape. The sublattices may have side surfaces shaped such that when the individual sublattices are bonded together to form the first and second end nodes of the support frame and the central node of the support frame, each of the first and second end nodes of the support frame and the central node of the support frame acquires a convex shape.

The sieve elements can be attached to the subgrids by at least one of a mechanical device, an adhesive, heat fusion, and ultrasonic welding.

In accordance with one exemplary embodiment of the present invention, a screen element is provided, comprising: a screening surface of the screen element having surface elements, the screens forming a group of screening holes; a pair of substantially parallel end portions; a pair of substantially parallel side edge portions substantially perpendicular to the end portions; the first support element of the sieve element; a second sieve element support element orthogonal to the first sieve element support element, wherein the first sieve element support element extends between the end portions and is approximately parallel to the side edge portions, the second sieve element support element extends between the side edge portions and is approximately parallel to the end portions and is substantially , perpendicular to the side edge parts; a first group of reinforcing elements substantially parallel to the side edge portions; and a second group of reinforcing elements substantially parallel to the end portions. The sieve surface elements run parallel to the end portions. The end parts, side edge parts, the first and second support elements, the first and second group of reinforcing elements structurally stabilize the elements of the screen surface and the screening holes, while the screen element is a single injection molded thermoplastic part.

In accordance with one exemplary embodiment of the present invention, there is provided a screen element having a screen element screen surface with screen surface elements forming a group of screen holes; a pair of substantially parallel end portions; and a pair of substantially parallel side edge portions substantially perpendicular to the end portions. The sieve element is a thermoplastic part obtained by injection molding.

The sieve element may also have a first support element of the sieve element; a second sieve element support element orthogonal to the first sieve element support element, wherein the first sieve element support element extends between the end portions and is approximately parallel to the side edge portion, the second sieve element support element extends between the side edge portions and is approximately parallel to the end portions; a first group of reinforcing elements substantially parallel to the side edge portions; and a second group of reinforcing elements substantially parallel to the end portions. The screen surface elements can run parallel to the end portions. In some embodiments, the screen surface elements can also be configured to extend perpendicular to the end portions. The end parts, the side edge parts, the first and second supporting elements, the first and second groups of reinforcing elements can structurally stabilize the screen surface elements and the screening holes.

The screen element may also have a screen element holder integrally molded with the screen element and configured to mate with the subgrid holder. A plurality of subgrids may form a sieve assembly, wherein the sieve assembly may have a continuous screening surface of a sieve assembly that includes a plurality of screening surfaces of the sieve elements.

In accordance with one exemplary embodiment of the present invention, there is provided a method for manufacturing a sieve assembly for screening materials, which includes the following: for the sieve assembly, the specifications of the sieve assembly are determined; determine the requirements for screening holes for the sieve element based on the technical characteristics of the sieve assembly, while the sieve element contains a screening surface of the sieve element having screening holes; determining a screen configuration based on the specifications of the screen assembly, the screen configuration including having screen elements arranged in at least one of a flat configuration and a non-planar configuration; sieve elements made of thermoplastic material are obtained by injection molding; subgrids are made that can serve as a support for sieve elements, moreover, the subgrid has a lattice frame with lattice openings, while at least one sieve element covers at least one lattice opening and is attached to the upper surface of the sublattice, and the upper surface of each sublattice includes itself at least one of a flat surface and a non-planar surface receiving the sieve elements; attaching the sieve elements to the subgrids; fastening a plurality of subgrid nodes together to form screen end frames and screen center frames; attaching the end frames of the screen to the center frames of the screen to form a frame structure of the screen; attaching the first connecting bar to the first end of the frame structure of the sieve; and attaching the second connecting bar to the second end of the frame structure of the sieve to obtain a sieve assembly, while the sieve assembly has a continuous screening surface of the sieve assembly, consisting of a plurality of screening surfaces of the sieve elements.

Screen assembly performance may include at least one of the following: dimensions, material requirements, screening area, separation boundary, and screening application capacity requirements. A handle can be attached to the connecting bar. A label may be affixed to the connecting bar, which label may include a description of the characteristics of the sieve assembly. At least one of the sieve element and subgrid may be a single injection molded thermoplastic piece. The thermoplastic material may include a nanomaterial. The sub-array may include at least one base element having fastening means that mate with the fastening means of other base elements of other sub-lattices and fasten the sub-lattices together. The fastening means may be latches and latch holes that snap into place and securely fasten the subgrids together.

In accordance with one exemplary embodiment of the present invention, there is provided a method for manufacturing a sieve assembly for screening materials, which includes the following: obtaining a sieve element by injection molding from a thermoplastic material, and the sieve element includes a screening surface of the sieve element having screening holes ; a sublattice is made that serves as a support for the sieve element, the sublattice having a lattice frame with lattice holes, the sieve element enclosing at least one lattice opening; attaching the sieve element to the upper surface of the subgrid; and fastening a plurality of subgrid nodes together to form a sieve assembly, wherein the sieve assembly has a continuous screening surface of the sieve assembly consisting of a plurality of screening surfaces of the sieve elements. The method may also include attaching a first connecting bar to the first end of the sieve assembly and attaching a second connecting bar.

- 9 039521 straps to the second end of the sieve unit. The first and second connecting strips can connect the subgrids together. The connecting bar can be configured to distribute the load along the first and second ends of the sieve assembly. The thermoplastic material may include a nanomaterial.

In accordance with one exemplary embodiment of the present invention, a method for screening material is provided, comprising the following: attaching a sieve assembly to a vibrating screen, the sieve assembly including a sieve element having a group of screening holes forming a screening surface of the sieve element, and a subgrid, including a plurality of elongated structural elements forming a lattice frame having lattice holes. The sieve elements cover the lattice openings and are attached to the upper surface of the sublattice. A plurality of subgrids are bonded together to form a sieve assembly. The sieve assembly has a continuous screening surface of the sieve assembly, consisting of a plurality of screening surfaces of the sieve elements. The sieve element is a single thermoplastic part obtained by injection molding. The material is screened using a sieve assembly.

In accordance with one exemplary embodiment of the present invention, a method for screening material is provided, comprising the following: attaching a sieve assembly to a vibrating screen and forming an upper screening surface of the sieve assembly into a concave shape. The sieve assembly includes a sieve element having a group of screening holes forming the screening surface of the sieve element, and a subgrid including a plurality of elongated structural elements forming a lattice frame having lattice holes. The sieve elements surround the grid openings and are attached to the upper surface of the subgrid. A plurality of subgrids are fastened together to form a sieve assembly, wherein the sieve assembly has a continuous screening surface of the sieve assembly consisting of a plurality of screening surfaces of the sieve elements. The sieve element is a single thermoplastic part obtained by injection molding. The material is screened using a sieve assembly.

In accordance with one exemplary embodiment of the present invention, a sieve assembly is provided, including: a sieve element having a first adhesive means; and a sublattice module having a second adhesive means. The first adhesive means and the second adhesive means may be made of different materials. At least one of the first adhesive agent and the second adhesive agent is activatable so that the sieve element and the subgrid can be bonded together. The sieve element is a single thermoplastic part obtained by injection molding.

The first adhesive means may be a plurality of hollow pockets on the lower surface of the sieve element, and the second adhesive means may be a plurality of fusible rods on the upper surface of the subgrid. The sieve element is made by microforming and has screening openings from about 40 to about 1000 microns. Hollow pockets can be oblong pockets. Fusible rods may have a height slightly greater than the depth of the hollow pockets. The depth of the hollow pockets can be approximately 0.05 inches (1.27 mm) and the height of the fusible rods is approximately 0.056 inches (1.42 mm). Fusible rods may have a width that is slightly less than the width of the hollow pockets.

The sieve element may include thermoplastic polyurethane. The sublattice may include nylon. The sieve assembly may include additional sieve elements and sub-grids bonded together, with a plurality of sub-grids bonded together. The sieve element may have a plurality of screen openings, which are elongated slots with a width and length, with the width of the screen openings ranging from about 43 to about 1000 microns between the inner surfaces of each element of the sieve surface. The sieve element can be attached to the subgrid by laser welding. The weld between the sieve element and the subgrid may include a mixture of the materials of the sieve element and the subgrid.

In accordance with one exemplary embodiment of the present invention, a sieve assembly is provided, including a sieve element having a screening surface of the sieve element with a group of screening holes; and a sublattice including a plurality of elongated structural elements forming a lattice frame having lattice holes. The sieve element covers at least one of the lattice openings and is attached to the upper surface of the sub-array. A plurality of individual subgrids are bonded together to form a sieve assembly, wherein the sieve assembly has a continuous screening surface of the sieve assembly consisting of a plurality of screening surfaces of the sieve elements. The sieve element includes substantially parallel end portions and substantially parallel side edge portions substantially perpendicular to the end portions. The sieve element further includes a first sieve element support element and a second sieve element support element orthogonal to the first sieve element support element, wherein the first sieve element support element extends between the end portions and is approximately parallel to the side edge portion, the second sieve element support element element extends between the side edge elements and is approximately parallel to the end portions. The sieve element contains the first group of reinforcing elements, essentially parallel to the side edge parts, and the second group of reinforcing elements, essentially parallel to the end parts. The screening surface of the sieve element includes elements of the sieve surface forming screening holes. The end parts, side edge parts, the first and second support elements, the first and second group of reinforcing elements structurally stabilize the sieve surface elements and screening holes. The sieve element is a single thermoplastic part obtained by injection molding. The sieve element includes a plurality of hollow pockets on the lower surface of the sieve element. The sublattice includes a plurality of fusible rods on the upper surface of the sublattice. Many fusible rods are made with the possibility of pairing with many hollow pockets.

The screen holes may be oblong slots with a width and length, with the width of the screen holes ranging from about 43 to about 1000 microns between the inner surfaces of each element of the screen surface. The plurality of fusible rods may have a height slightly greater than the depth of the plurality of hollow pockets. The height of the plurality of fusible rods may be approximately 0.056 inches (1.42 mm). The depth of the plurality of hollow pockets may be approximately 0.050 inches (1.27 mm). Each of the plurality of hollow pockets may have a width slightly greater than the width of each of the plurality of fusible rods. The plurality of fusible rods may be configured such that, when melted, portions of the plurality of fusible rods fill the width of the plurality of hollow pockets. The material of the sieve element may be fused with the material of the subgrid. The sieve element may be configured to allow the laser to pass through the sieve element and contact a plurality of fusible rods. The laser can melt parts of a plurality of fusible rods by fusing the sieve element to the sublattice.

The subgrid may be a single injection molded thermoplastic piece. The sieve element may include 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 comprise a nylon material. Fusible rods may include at least one of carbon and graphite material. The subarray may include a sieve element positioner configured to position the sieve element on the subarray. The sieve element may include a plurality of tapered reciprocal channels on the upper surface of the sieve element along side edge portions and end portions between the positioning holes of the positioner. Fusible rods and hollow pockets can be made from different materials.

The lattice frame may include a first and a second lattice frame forming the first and second lattice openings, the sieve elements including the first and second sieve elements. The subgrid may include a ridge portion and a base portion, the first and second lattice frames include first and second inclined surfaces that form a peak on the ridge portion and extend obliquely downward from the peak to the base portion, the first and second sieve elements enclosing the first and second inclined surfaces, respectively. The screen assembly may include a secondary support frame enclosing at least a portion of each screen opening.

In accordance with one exemplary embodiment of the present invention, a screen assembly is provided, including: a screen element including a screening surface of the screen element having a group of screening holes, and a plurality of hollow pockets of the bottom surface of the screen element; and a sublattice including a plurality of elongated structural elements forming a lattice frame having lattice holes and a plurality of fusible rods on the upper surface of the sublattice. The sieve element covers at least one lattice opening and is attached to the upper surface of the sub-array by fusing a plurality of fusible rods with a plurality of hollow pockets. A plurality of subgrids are fastened together to form a sieve assembly, wherein the sieve assembly has a continuous screening surface of the sieve assembly consisting of a plurality of screening surfaces of the sieve elements. The sieve element is a single thermoplastic part obtained by injection molding. The sieve element may be configured to allow the laser to pass through the sieve element and contact a plurality of fusible rods.

The screen holes may be elongated slits having a width and length, with the width of the screen holes ranging from about 43 to about 1000 microns between the inner surfaces of each element of the screen surface. The screen holes may be oblong slits in width and length, with the width of the screen holes ranging from about 70 to about 180 microns between the inner surfaces of each element of the screen surface. The screen holes may be oblong slits, width and length, with the width of the screen holes ranging from about 43 to about 106 microns between the inner surfaces of each element of the screen surface. The screening holes may be elongated slits having a width and length between about 0.044 to about 4 mm wide and about 0.088 to about 60 mm long.

The sublattice may include substantially parallel triangular end elements, triangular middle elements substantially parallel to the triangular end elements, first and second middle supports substantially perpendicular to the triangular end elements and extending between the triangular end elements, first and second base a support essentially perpendicular to the triangular end elements and passing between the triangular end elements, and a central ridge essentially perpendicular to the triangular end elements and passing between the triangular end elements, wherein the first edge of the triangular end elements, the triangular middle elements, the first middle support, the first base support and the central ridge form the first upper surface of the sublattice, having the first group of lattice holes, and the second edge of the triangular end elements, the triangular middle elements, the second middle support, the second base support and the central ridge form in a second upper surface of the subgrid having a second group of lattice holes, the first upper surface extending at an angle from the central ridge to the first base leg, the second upper surface extending at an angle from the central ridge to the second base leg. The first and second screen elements may surround the first group and the second group of grid holes, respectively.

In exemplary embodiments of the present invention, a method for manufacturing a sieve assembly is provided, including: laser welding a sieve element of a first material with a sublattice of a second material; and bonding the plurality of subgrids together to form a sieve assembly. The first material and the second material are different materials. The first material and the second material are fused together at the location of the laser weld.

The sieve assembly may have a first adhesive on the bottom surface of the sieve element, and the subgrid has a second adhesive on the top surface of the subgrid. The first adhesive means may be a plurality of hollow pockets and the second adhesive means may be a plurality of fusible rods. A plurality of hollow pockets may be configured to mate with a plurality of fusible rods.

The method for manufacturing a sieve assembly may include placing a sieve element on a sub-array using positioning holes in the sieve element and positioning protrusions on the upper surface of the sub-array. The method for manufacturing the sieve assembly may include allowing a laser to pass through the sieve element so that it contacts a plurality of fusible rods. A method for manufacturing a sieve assembly may include melting a portion of a plurality of fusible rods with a laser. The method for manufacturing the sieve assembly may include melting a portion of the first material by one of the following: laser-induced heating and heat transfer from molten portions of a plurality of fusible rods. The method for manufacturing the sieve assembly may include retracting the laser so that the melted portion of the first material and the melted portion of the fusible rods mix and return to a solid state.

Exemplary embodiments of the present invention are described in more detail below with reference to the accompanying drawings.

List of drawings

In FIG. 1 is an isometric view of a sieve assembly in accordance with one exemplary embodiment of the present invention.

In FIG. 1A is an enlarged view of a fragment of the sieve assembly of FIG. one.

In FIG. 1B is a bottom isometric view of the sieve assembly of FIG. one.

In FIG. 2 shows a top isometric view of a sieve element in accordance with one exemplary embodiment of the present invention.

In FIG. 2A is a plan view of the sieve element of FIG. 2.

In FIG. 2B is an isometric bottom view of the sieve element of FIG. 2.

In FIG. 2C is a bottom view of the sieve element of FIG. 2.

In FIG. 2D is an enlarged plan view of a fragment of the sieve element of FIG. 2.

In FIG. 3 shows an isometric plan view of an end sub-array according to one exemplary embodiment of the present invention.

In FIG. 3A is a bottom isometric view of the end sub-grating of FIG. 3.

In FIG. 4 is an isometric plan view of a central sub-grid in accordance with one exemplary embodiment of the present invention.

In FIG. 4A is an isometric view from below of the central sublattice of FIG. 4.

In FIG. 5 shows a top isometric view of a connecting bar according to one exemplary embodiment of the present invention.

In FIG. 5A is a bottom isometric view of the connecting strip of FIG. 5.

In FIG. 6 is an isometric view of a sieve subassembly in accordance with one exemplary embodiment of the present invention.

In FIG. 6A is an exploded view of the subassembly of FIG. 6.

In FIG. 7 is a plan view of the sieve assembly of FIG. one.

In FIG. 7A is an enlarged sectional view of the section A-A of the sieve assembly of FIG. 7.

In FIG. 8 shows a top isometric view of a sieve assembly partially covered with sieve elements, in accordance with one exemplary embodiment of the present invention.

In FIG. 9 is an exploded isometric view of the sieve assembly of FIG. one.

In FIG. 10 is an exploded isometric view of an end sub-array showing sieve elements prior to attachment to the end sub-array, in accordance with one exemplary embodiment of the present invention.

In FIG. 10A is an isometric view of the end sublattice of FIG. 10 with sieve elements attached thereto.

In FIG. 10B is a plan view of the end sub-grating of FIG. 10A.

In FIG. 10C is a section B-B of the end sublattice of FIG. 10A.

In FIG. 11 is an exploded isometric view of the central sub-array showing the sieve elements prior to being attached to the central sub-array, in accordance with one exemplary embodiment of the present invention.

In FIG. 11A is an isometric view of the central sublattice of FIG. 11 with sieve elements attached thereto.

In FIG. 12 is an isometric view of a vibrating screen with concave screen assemblies installed therein, in accordance with one exemplary embodiment of the present invention.

In FIG. 12A is an enlarged isometric view of the discharge end of the vibrating screen of FIG. 12.

In FIG. 12B is a front view of the vibrating screen of FIG. 12.

In FIG. 13 is an isometric view of a single screen vibrating screen having screen assemblies installed therein with concave screen surfaces, in accordance with one exemplary embodiment of the present invention.

In FIG. 13A is a front view of the vibrating screen of FIG. thirteen.

In FIG. 14 is a front view of a vibrating screen comprising two separate concave screen surfaces with prefabricated screen assemblies mounted on the vibrating screen, in accordance with one exemplary embodiment of the present invention.

In FIG. 15 is a front view of a vibrating screen comprising a single screening surface with a complete screen assembly mounted on the vibrating screen, in accordance with one exemplary embodiment of the present invention.

In FIG. 16 is an isometric view of an end subassembly of a support frame in accordance with one exemplary embodiment of the present invention.

In FIG. 16A is an exploded isometric view of the end subassembly of the support frame of FIG. sixteen.

In FIG. 17 is an isometric view of a central support frame subassembly in accordance with one exemplary embodiment of the present invention.

In FIG. 17A is an exploded isometric view of the central support frame subassembly of FIG. 17.

In FIG. 18 is an exploded isometric view of a sieve assembly in accordance with one exemplary embodiment of the present invention.

In FIG. 19 is an isometric plan view of a flat screen assembly in accordance with one exemplary embodiment of the present invention.

In FIG. 20 is an isometric top view of a convex sieve assembly in accordance with one exemplary embodiment of the present invention.

In FIG. 21 is an isometric view of a sieve assembly containing pyramid-shaped sub-grids according to one exemplary embodiment of the present invention.

In FIG. 21A is an enlarged sectional view D of the sieve assembly of FIG. 21.

In FIG. 22 is a plan isometric view of a pyramid-shaped end sub-array according to one exemplary embodiment of the present invention.

In FIG. 22A is a bottom isometric view of the pyramid-shaped end sublattice of FIG. 22.

In FIG. 23 is a plan isometric view of a pyramid-shaped central sublattice in accordance with one exemplary embodiment of the present invention.

In FIG. 23A is a bottom isometric view of the pyramidal-shaped central sublattice of FIG. 23.

In FIG. 24 is an isometric view of a pyramid-shaped subassembly in accordance with one exemplary embodiment of the present invention.

- 13 039521

In FIG. 24A is an exploded isometric view of the pyramid-shaped subassembly of FIG. 24.

In FIG. 24B is an exploded isometric view of the pyramid-shaped end sub-array showing the sieve elements before being attached to the pyramid-shaped end sub-array.

In FIG. 24C is an isometric view of the pyramidal end sublattice of FIG. 24B with sieve elements attached thereto.

In FIG. 24D is an exploded isometric view of the pyramidal central subarray showing the sieve elements before being attached to the pyramidal central subarray, in accordance with one exemplary embodiment of the present invention.

In FIG. 24E is an isometric view of the pyramid-shaped central sublattice of FIG. 24D with sieve elements attached thereto.

In FIG. 25 is a plan view of a sieve assembly containing pyramid-shaped sub-grids, in accordance with one exemplary embodiment of the present invention.

In FIG. 25A is a sectional view, section C-C, of the sieve assembly of FIG. 25.

In FIG. 25B is an enlarged sectional view C-C of FIG. 25A.

In FIG. 26 is an exploded isometric view of a sieve assembly comprising pyramidal and flat subassemblies in accordance with one exemplary embodiment of the present invention.

In FIG. 27 is an isometric view of a double screen vibrating screen having concave screen surface assemblies installed therein, the screen assemblies including pyramidal and flat subassemblies in accordance with one exemplary embodiment of the present invention.

In FIG. 28 shows a top isometric view of a sieve assembly comprising pyramidal and flat sub-arrays, without sieve elements, according to one exemplary embodiment of the present invention.

In FIG. 29 is a top isometric view of the sieve assembly of FIG. 28 where the sublattices are partially covered by sieve elements.

In FIG. 30 is a front view of a double screen vibrating screen having concave screen assemblies installed therein, the screen assemblies including pyramidal and flat sub-grids, in accordance with one exemplary embodiment of the present invention.

In FIG. 31 is a front view of a single screen vibrating screen having a concave screen assembly installed therein, the screen assembly including pyramidal and flat sub-grids, in accordance with one exemplary embodiment of the present invention.

In FIG. 32 is a front view of a double screen vibrating screen having prefabricated flat screen screen assemblies installed therein, the screen assemblies including pyramidal and flat sub-grids, in accordance with one exemplary embodiment of the present invention.

In FIG. 33 is a front view of a single screen vibrating screen having a complete flat screen screen assembly mounted therein, the screen assembly including pyramidal and flat sub-grids, in accordance with one exemplary embodiment of the present invention.

In FIG. 34 is an isometric view of the end sublattice of FIG. 3 with one sieve element partially attached thereto, in accordance with one exemplary embodiment of the present invention.

In FIG. 35 is an enlarged view of a fragment E of the end sublattice of FIG. 34.

In FIG. 36 is an isometric view of a sieve assembly including pyramid-shaped sub-grids in a portion of the sieve assembly, in accordance with one exemplary embodiment of the present invention.

In FIG. 37 is a diagram of a manufacturing process for a sieve assembly in accordance with one exemplary embodiment of the present invention.

In FIG. 38 is a diagram of a manufacturing process for a sieve assembly in accordance with one exemplary embodiment of the present invention.

In FIG. 39 is an isometric view of a vibrating screen assembly having a single flat screen screen assembly mounted therein, with a portion of the vibrating screen removed to show the screen assembly, in accordance with one exemplary embodiment of the present invention.

In FIG. 40 is an isometric plan view of a single sieve element in accordance with one exemplary embodiment of the present invention.

In FIG. 40A shows a top isometric view of a pyramid of sieve elements according to one exemplary embodiment of the present invention.

In FIG. 40B is an isometric top view of the four sieve stacks of FIG. 40A.

- 14 039521

In FIG. 40C is a top isometric view of an inverted sieve pyramid in accordance with one exemplary embodiment of the present invention.

In FIG. 40D is a front view of the sieve element of FIG. 40C.

In FIG. 40E shows a top isometric view of a sieve element structure according to one exemplary embodiment of the present invention.

In FIG. 40F is a front view of the sieve element structure of FIG. 40E.

In FIG. 41-43 show cross-sectional front views of sieve elements in accordance with exemplary embodiments of the present invention.

In FIG. 44 is an isometric plan view of a pre-screen structure with pre-screen assemblies, in accordance with one exemplary embodiment of the present invention.

In FIG. 44A is a top isometric view of the pre-sieve assembly of FIG. 44, in accordance with one exemplary embodiment of the present invention.

In FIG. 45 is a plan view of a sieve element above a sub-grid portion, in accordance with one exemplary embodiment of the present invention.

In FIG. 45A is an exploded sectional view, section A-A, showing the sieve element above the subgrid portion of FIG. 45.

In FIG. 45B is a sectional side view A-A of the sieve element and part of the subgrid of FIG. 45 prior to attaching the sieve element to the subgrid, in accordance with one exemplary embodiment of the present invention.

In FIG. 45C is an enlarged view of detail A in FIG. 45V.

In FIG. 45D is a sectional side view A-A of the sieve element and part of the subgrid of FIG. 45 after attaching the sieve element to the subgrid, in accordance with one exemplary embodiment of the present invention.

In FIG. 45E is an enlarged view of detail B in FIG. 45D.

In FIG. 46 is a sectional side view of a portion of a sieve element and a portion of a subgrid according to one exemplary embodiment of the present invention.

In FIG. 47 is an isometric plan view of a portion of a sieve assembly in accordance with one exemplary embodiment of the present invention.

In FIG. 48 shows a top isometric view of a sieve element according to one exemplary embodiment of the present invention.

In FIG. 48A is a plan view of the sieve element of FIG. 48.

In FIG. 48B is a bottom isometric view of the sieve element of FIG. 48.

In FIG. 48C is a bottom view of the sieve element of FIG. 48.

In FIG. 49 is an isometric plan view of an end sub-array in accordance with one exemplary embodiment of the present invention.

In FIG. 49A is a bottom isometric view of the end sub-grating of FIG. 49.

In FIG. 50 is an isometric plan view of a central sub-array according to one exemplary embodiment of the present invention.

In FIG. 50A is a bottom isometric view of the central sub-lattice of FIG. fifty.

In FIG. 51 is an exploded isometric view of an end sub-array showing sieve elements prior to being attached to an end sub-array, in accordance with one exemplary embodiment of the present invention.

In FIG. 51A is an isometric view of the end sublattice of FIG. 51 with sieve elements attached thereto.

In FIG. 52 is an exploded isometric view of the central sub-array showing the sieve elements prior to attachment to the central sub-array, in accordance with one exemplary embodiment of the present invention.

In FIG. 52A is an isometric view of the central sublattice of FIG. 52 with sieve elements attached thereto.

In FIG. 53 is a top isometric view of a pyramid-shaped end sub-array according to one exemplary embodiment of the present invention.

In FIG. 53A is a bottom isometric view of the pyramidal end sublattice of FIG. 53.

In FIG. 54 is a plan isometric view of a pyramid-shaped central sublattice in accordance with one exemplary embodiment of the present invention.

In FIG. 54A is a bottom isometric view of the pyramid-shaped central sublattice of FIG. 54.

In FIG. 55 is an exploded isometric view of a pyramidal end subarray showing the sieve elements prior to attachment to the pyramidal end subarray, in accordance with one exemplary embodiment of the present invention.

In FIG. 55A is an isometric view of the pyramidal end sublattice of FIG. 55, with

- 15 039521 sieve elements attached to it.

In FIG. 56 is an exploded isometric view of the pyramid-shaped central sub-array showing the sieve elements before being attached to the pyramid-shaped central sub-array, in accordance with one exemplary embodiment of the present invention.

In FIG. 56A is an isometric view of the pyramid-shaped central sublattice of FIG. 56 with sieve elements attached thereto.

In FIG. 57 is an isometric view of the end sublattice of FIG. 50 with one screen element partially attached thereto, in accordance with one exemplary embodiment of the present invention.

In FIG. 57A is an enlarged view of detail A of the end sublattice of FIG. 57.

In FIG. 58 shows a top isometric view of a portion of a sieve assembly in accordance with one exemplary embodiment.

In FIG. 59 shows an isometric plan view of an end sub-array according to one exemplary embodiment.

In FIG. 59A is a bottom isometric view of the end sub-array of FIG. 59.

In FIG. 60 shows a top isometric view of a central sub-array according to one exemplary embodiment.

In FIG. 60A is a bottom isometric view of the central sub-lattice of FIG. 60.

In FIG. 61 is an exploded isometric view of an end sub-array showing the sieve elements prior to being attached to the end sub-array, in accordance with one exemplary embodiment.

In FIG. 61A is an isometric view of the end subgrid of FIG. 61 with sieve elements attached thereto, in accordance with one exemplary embodiment.

In FIG. 62 is an exploded isometric view of the central sub-array showing the sieve elements prior to attachment to the central sub-array, in accordance with one exemplary embodiment.

In FIG. 62A is an isometric view of the central sublattice of FIG. 62 with sieve elements attached thereto, in accordance with one exemplary embodiment.

In FIG. 63 is a plan isometric view of a pyramidal end sub-array according to one exemplary embodiment.

In FIG. 63A is a bottom isometric view of the pyramidal end sublattice of FIG. 63.

In FIG. 63B is an isometric view of latch 42 of FIG. 3 and 3A according to one embodiment.

In FIG. 63C is an isometric view of latch 142 of FIG. 59-62A, according to one embodiment.

In FIG. 63D is an isometric view of latch 242 of FIG. 63 and 63A, according to one embodiment.

In FIG. 64 shows an isometric plan view of an end sub-array according to one exemplary embodiment.

In FIG. 64A is a bottom isometric view of the end sub-array of FIG. 64.

In FIG. 65 shows a top isometric view of a central sub-array according to one exemplary embodiment.

In FIG. 65A is a bottom isometric view of the central sublattice of FIG. 65.

In FIG. 66 shows a top isometric view of a sieve element according to one exemplary embodiment of the present invention.

In FIG. 66A is a plan view of the sieve element of FIG. 66.

In FIG. 66B is a bottom isometric view of the sieve element of FIG. 66.

In FIG. 66C is a bottom view of the sieve element of FIG. 66.

In FIG. 67 is an exploded isometric view of the end sub-array showing the screen element prior to attachment to the end sub-array, in accordance with one exemplary embodiment.

In FIG. 67A is an isometric view of the end subgrid of FIG. 67 with a sieve element attached thereto, in accordance with one exemplary embodiment.

In FIG. 68 is an exploded isometric view of the central sub-array showing the sieve element prior to being attached to the central sub-array, in accordance with one exemplary embodiment.

In FIG. 68A is an isometric view of the central sublattice of FIG. 68 with a sieve element attached thereto, in accordance with one exemplary embodiment.

In FIG. 69 is an isometric view of a sieve assembly containing pyramid-shaped sub-grids, in accordance with one exemplary embodiment of the present invention.

In FIG. 69A is an enlarged view of detail D of the sieve assembly in FIG. 69.

- 16 039521

In FIG. 70 reproduces FIG. 66C illustrating a bottom view of the sieve element, for comparison with the sieve element of FIG. 70A.

In FIG. 70A is a bottom view of a sieve element having smaller structural elements than the sieve element shown in FIG. 70 and 66.

In FIG. 71 reproduces FIG. 65 illustrating an isometric plan view of the central sub-array for comparison with the central sub-array of FIG. 71A.

In FIG. 71A shows an isometric side view of a central sub-array according to one embodiment.

In FIG. 71B is an enlarged view of detail A in FIG. 71A, in accordance with one embodiment.

In FIG. 71C is a plan view of the central sub-lattice of FIG. 71A, in accordance with one embodiment.

In FIG. 71D is a side view of the central sub-grid of FIG. 71A, in accordance with one embodiment.

In FIG. 71E shows the structural elements of a sieve element in comparison with the supporting structural elements of the end subgrid, in accordance with one embodiment.

In FIG. 71F shows the structural elements of another sieve element compared to the supporting structural elements of another end sub-array, in accordance with one embodiment.

In FIG. 72 shows a pyramid-shaped end sub-array similar to the pyramid-shaped end sub-array in FIG. 63 for comparison with the pyramidal end sublattice of FIG. 72A.

In FIG. 72A shows a pyramidal end sublattice having a higher linear density of structural elements than in FIG. 72, in accordance with one embodiment.

In FIG. 72B shows the structural elements of a sieve element in comparison with the supporting structural elements of a pyramidal end subarray, in accordance with one embodiment.

In FIG. 72C shows the structural elements of another sieve element in comparison with the supporting structural elements of another pyramid-shaped end subarray, in accordance with one embodiment.

In FIG. 73 is a plan view of the sieve element previously shown in FIG. 70A, 71F, and 72C, on which a first cross-sectional direction A-A and a second cross-sectional direction C-C are defined, in accordance with one embodiment.

In FIG. 73A shows a first cross section defined by the first cross section direction A-A in FIG. 73, in accordance with one embodiment.

In FIG. 73B is an enlarged view of the first cross section of FIG. 73A, in accordance with one embodiment.

In FIG. 73C shows a second cross section of the sieve element of FIG. 73 defined by the second C-C cross-sectional direction of FIG. 73, in accordance with one embodiment.

In FIG. 73D is an enlarged view of the second cross section of FIG. 73C, in accordance with one embodiment.

In FIG. 74 is a plan view of a central sieve subassembly similar to the central sieve assembly shown in FIG. 68A, in which the cross-sectional direction A-A is defined, in accordance with one embodiment.

In FIG. 74A is a side view of the central sieve assembly of FIG. 74, in accordance with one embodiment.

In FIG. 74B shows a cross section defined by the cross section direction A-A in FIG. 74, in accordance with one embodiment.

In FIG. 74C is a first enlarged view of a first sectional view of the central sieve subassembly of FIG. 74B, in accordance with one embodiment.

In FIG. 74D is a second enlarged view of a second sectional view of the central sieve subassembly of FIG. 74C, in accordance with one embodiment.

In FIG. 75 shows screen subassemblies attached to rectangular areas formed by a lattice frame formed by the first and second plurality of crossbars, in accordance with one embodiment.

In FIG. 76 shows sieve elements directly attached to the plate structure without the need to first attach the sieve elements to the sub-grids, in accordance with an embodiment.

In FIG. 76A shows sieve elements designed to be directly attached to a perforated plate, in accordance with one embodiment.

- 17 039521

In FIG. 76B shows screen elements designed to be directly attached to a corrugated perforated plate, in accordance with one embodiment.

In FIG. 76C shows a frame having pockets for accommodating screen elements, in accordance with one embodiment.

In FIG. 77A shows an embodiment of a fusible rod that can serve as a positioning element, in accordance with one embodiment.

In FIG. 77B shows an embodiment of a hollow pocket that can serve as a positioning hole, in accordance with one embodiment.

In FIG. 77C shows the alignment of the fusible rod of FIG. 77A with the hollow pocket of FIG. 77B.

Information confirming the possibility of carrying out the invention

Like reference numerals designate like parts throughout the several drawings.

Embodiments of the present invention provide a sieve assembly including injection molded sieve elements coupled to a subgrid. A plurality of subgrids are securely attached to each other to form a vibrating screen assembly having a continuous screening surface for use in a vibrating screen. The whole structure of the sieve assembly is designed to withstand the severe load conditions that occur during installation and operation in a vibrating screen. Injection molded sieve elements offer many advantages in screen assembly and vibratory screening applications. In some embodiments of the present invention, the sieve elements are injection molded using a thermoplastic material. In some embodiments of the present invention, the sieve elements may have a first adhesive means configured to mate with a second adhesive means on the subgrid. The first and second adhesive means may include different materials and may be designed such that the screen elements can be laser welded to the sub-grid. The first adhesive means may be a plurality of hollow pockets, and the second adhesive means may be a plurality of fusible rods, which may be made to melt under the influence of a laser. The screen elements may contain thermoplastic polyurethane, which may be based on polyester (polyester) or polyether. Embodiments of the present invention include sieve elements attached to subgrids by a cured mixture of separate materials. Embodiments of the present invention include methods for making a sieve assembly by fusing sieve elements to sub-arrays using laser welding and bonding a plurality of sub-arrays together to form a sieve assembly.

Embodiments of the present invention provide injection-molded screen elements that are sized and configured to be optimal for making vibrating screen assemblies and for use in vibrating screening. Several important considerations were taken into account in the configuration of the individual sieve elements. The sieve elements are designed to be optimally sized (large enough to effectively mount the entire sieve assembly structure, but small enough to be injection molded (micromolded in some embodiments) of extremely small screen hole structures without solidification (i.e. e. solidification of the material in the form until it is completely filled)); have an optimal screening area (designs that form holes and support the holes are of a minimum size to increase the total screening area used for screening while maintaining, in some embodiments, very small screening holes necessary for proper separation of materials to a given standard); have durability and strength, can work in various temperature ranges; chemically resistant; structurally stable; highly versatile for sieve assembly manufacturing processes; and are configured to provide customized configurations for specific applications.

Embodiments of the present invention provide sieve elements that are manufactured using extremely precise injection molding. The larger the sieve element, the easier it is to mount the entire vibrating sieve assembly. Simply put, the fewer parts you need to assemble, the easier it will be to assemble the system. However, the larger the sieve element, the more difficult it is to obtain extremely small structures by injection molding, i.e. structures that form screening holes. It is important to minimize the size of the structures that form the screening holes in order to maximize the number of screening holes on an individual screen element, optimizing the screening area for the screening element and, therefore, for the entire screen assembly. In some embodiments, sieve elements are provided that are large enough (e.g., one inch by one inch (-25.4x25.4 mm), one inch by two inches (-25.4x50.8 mm), two inches by three inches (-50.8x76.2 mm), etc.) to realize the installation of the entire screening surface of the sieve assembly (for example, two feet by three feet (-60x90 cm), three feet by four feet (-90x120 cm), etc. .d.). Relatively small size (for example, one inch by one inch (-25.4x25.4 mm),

- 18 039521 one inch by two inches (-25.4x50.8 mm), two inches by three inches (-50.8x76.2 mm), etc.) is large enough to microform extremely small structural elements (for example, structural elements up to 43 µm in size). The larger the size of the entire screen element and the smaller the size of the individual structural elements that form the screening holes, the more the injection molding process is susceptible to defects such as solidification. Thus, the size of the sieve elements must be suitable for the fabrication of sieve assemblies, and at the same time small enough to avoid problems such as curing when microforming extremely small structures. The dimensions of the screening elements can vary depending on the injection molding material, the size of the screening holes required and the total screening area required. Screening free area is a critical parameter of vibrating screens. The average serviceable screening area (ie the actual screening area including structural steel of support members and binders) for conventional 100-200 mesh wire mesh assemblies can be in the 16% range. Particular embodiments of the present invention (eg, screen assemblies of the designs disclosed herein and having screen openings of 100-200 mesh) provide screen assemblies in the same range having similar actual screening clearances. Conventional screens, however, clog fairly quickly in service, resulting in a fairly rapid reduction in the actual screening area. It is not uncommon for traditional metal screens to clog within the first 24 hours of operation, reducing the actual screening area by 50%. Traditional wire assemblies also often fail due to the wire being subjected to vibrational forces that place bending loads on the wire. In contrast, injection-molded screen assemblies according to embodiments of the present invention do not experience severe clogging (thus maintaining a relatively constant actual screening area) and rarely fail due to the structural stability and configuration of a screen assembly containing sieve elements and sublattice structures. In fact, screen assemblies according to embodiments of the present invention have an extremely long service life and can be operated for long periods of time under high load. Screen assemblies according to the present invention have been tested for months under harsh conditions without breakage or clogging, while traditional wire assemblies, which have been tested under the same conditions, clog and fail within days. As discussed in more detail herein, conventional thermoset type assemblies cannot be used for such an application.

In embodiments of the present invention, a thermoplastic is used to produce screen elements by injection molding. Unlike thermoset-type polymers, which often include liquid materials that react chemically and are subject to thermal curing, the use of thermoplastics is often simpler and can be achieved, for example, by melting a homogeneous material (often in the form of solid granules) and then making injection molding of molten material. In addition to the fact that the physical properties of thermoplastics are optimal in vibratory screening applications, the use of thermoplastic fluids simplifies manufacturing processes, especially in micromolded parts, as disclosed herein. The use of thermoplastic materials in the present invention provides excellent flexural strength and flexural fatigue strength and is optimal for parts subjected to intermittent heavy loading or continuous heavy loading, as occurs with vibrating screens used in vibrating screens. As the vibrating screens move, the low friction coefficient of thermoplastic injection molding materials ensures optimum wear characteristics. Indeed, the wear resistance of some thermoplastics is superior to that of many metals. In addition, the use of thermoplastics, as disclosed herein, provides an optimum snap-on material due to its strength and elongation characteristics. The use of thermoplastics in embodiments of the present invention also provides resistance to stress cracking, aging, and extreme weathering. The thermal deflection temperature of thermoplastics is in the 200°F (-93.3°C) range. With the addition of fiberglass, it increases to approximately 250-300°F (-121.1-148.9°C) or higher and increases the stiffness, measured by flexural modulus, from approximately 400,000 psi (-2.76 GPa) to over 1,000,000 psi (-6.89 GPa). All these properties are optimal for the conditions that arise when using vibrating screens in vibrating screens in difficult operating conditions.

Embodiments of the present invention may provide different materials in the subgrid modules and/or sieve elements depending on the desired properties according to the embodiments. Thermoplastic polyurethane (TPU) can be incorporated into embodiments of the present invention (eg, sieve elements) to provide elasticity, transparency, and resistance to oils, fats, and abrasion. TPU also has high shear strength. These TPU properties are useful in connection with embodiments of the present invention that are used

- 19 039521 subject to high vibration forces, abrasive materials and high load requirements. In embodiments, different types of TPUs may be used depending on the material being screened. For example, polyester (polyester) based TPUs can be included in screen assemblies used for screening applications in the oil and gas industry because the esters provide superior abrasion resistance, oil resistance, mechanical integrity, chemical resistance, and adhesion strength. Polyether based TPUs can be used in the mining industry where resistance to hydrolysis is important (a property of ether based TPUs). Embodiments of the present invention may include paraphenylene diisocyanate (PPDI). PPDI can provide high performance properties in various screening applications. Materials for embodiments of the present invention may be selected or determined based on a variety of factors, including the performance of each material and the costs associated with using the materials.

In embodiments of the present invention, sieve element materials can be selected to have high temperature tolerance, chemical resistance, hydrolytic resistance, and/or abrasion resistance. The screen elements may contain materials such as thermoplastic polyurethanes (TPU) to provide a transparent appearance to the screen elements. Transparent sieve elements can effectively pass the laser through the sieve elements for laser welding purposes. The materials of the subgrids may differ from the material of the sieve element. In embodiments of the present invention, the subgrids may be nylon. The sublattices may contain carbon or graphite. Different materials between screen elements and sub-grids can be attached to each other by laser welding, which can provide much stronger adhesion between the screen elements and sub-grids than alternative methods of fastening. Stronger attachment of the sieve element to the subgrid provides improved performance of the sieve assemblies when exposed to the high vibratory forces of vibrating screens and the abrasion forces that occur on the surfaces of the sieve elements during screening of materials.

In FIG. 1 shows a screen assembly 10 for use with vibrating screens. The sieve assembly 10 is shown with a plurality of sieve elements 16 (see, for example, FIGS. 2 and 2A-2D) mounted on sub-array structures. The sublattice structures include a plurality of individual end sublattice modules 14 (see, for example, FIG. 3) and a plurality of individual central sublattice modules 18 (see, for example, FIG. 4) that are fastened together to form a lattice frame having lattice openings. 50. Each sieve element 16 encloses four lattice openings 50. Although the sieve element 16 is shown as a module covering four lattice openings, the sieve elements can be made in larger or smaller modules. For example, a sieve element may be provided that is approximately one-quarter the size of sieve element 16 so that it spans one grid opening 50. Alternatively, a sieve element may be provided that is approximately twice the size of sieve element 1 so that it will span all eight grid openings of the sub-grid 14 or 18. Sub-grids of different sizes can also be provided. For example, modules of sublattices can be provided that have two lattice openings per module, or one large sublattice can be provided for the entire structure, i. e. one subgrid design for the entire sieve assembly. In FIG. 1, a plurality of individual subgrids 14 and 18 are bonded together to form a sieve assembly 10. The sieve assembly 10 has a continuous screening surface 11 of the sieve assembly, which includes a plurality of screening surfaces 13 of the sieve elements. Each screen element 16 is a single injection molded thermoplastic piece.

In FIG. 1A is an enlarged view of a detail of a sieve assembly 10 having a plurality of end sub-grids 14 and center sub-grids 18. As will be discussed below, end sub-grids 14 and center sub-grids 18 may be bonded together to form a sieve assembly. The sieve elements 16 are shown attached to the end sub-grids 14 and the center sub-grids 18. The size of the sieve assembly can be changed by bonding more or fewer sub-grids together to form the sieve assembly. When installed in a vibrating screen, the material may be fed to the sieve assembly 10. See, for example, FIG. 12, 12A, 12B, 13, 13A, 14 and 15. Material that is smaller than the sieve openings of the sieve element 16 passes through the openings in the sieve element 16 and through the grid openings 50, and is separated from the material that is too large. for passing through the screening holes of the sieve elements 16.

In FIG. 1B shows a bottom view of the screen assembly 10 so that the screen openings 50 can be seen under the screen elements. Link bars 12 are attached to the sides of the screen frame. The connecting strips 12 may comprise locking means which are fastened to the locking means on the side elements 38 of the sublattice modules (14 and 18) or to the fixing means on the base element 64 of the pyramidal modules (58 and 60) of the sublattices. Connecting bars 12 can be provided to increase the stability of the screen frame and can distribute compression loads if the screen assembly is mounted on a vibrating screen using compression, for example

- 20 039521 measures, using compression units, as disclosed in US patent No. 7578394 and US patent application No. 12/460200 (currently US patent No. 8443984). Link bars may also be provided that include U-shaped members or finger-receiving holes for tension when mounted top or bottom on a vibrating screen, for example, see mounting structures disclosed in US Pat. Nos. 5,332,101 and 6,696,927. the elements and subgrids are securely fastened together, as disclosed herein, so that even under tension, the screening surface of the sieve assembly and the sieve assembly retain their structural integrity.

The sieve assembly shown in Fig. 1 is slightly concave, i.e. the lower and upper surfaces of the sieve assembly have a slight curvature. The sublattices 14 and 18 are made in such a way that a predetermined curvature is achieved during their assembly. Alternatively, the sieve assembly may be flat or convex (see, for example, FIGS. 19 and 20). As shown in FIG. 12, 12A, 13 and 13A, screen assembly 10 may be mounted on a vibrating screen having one or more screening surfaces. In one embodiment, the screen assembly 10 may be mounted on a vibrating screen by placing the screen assembly 10 on the vibrating screen such that the link bars are in contact with the end or side members of the vibrating screen. A compressive force is then applied to the connecting bar 12. The connecting strips 12 distribute the load from the compressive force on the sieve assembly. The screen assembly 10 can be configured to flex and deform into a predetermined concave shape when a compression force is applied to the connecting bar 12. The amount of deformation and the range of concavity can vary depending on the application, the applied compression force, and the shape of the vibrating screen support bed. Compressing the screen assembly 10 into a concave shape when installed in a vibrating screen provides many advantages, such as simple and easy installation and removal, gripping and centering of materials to be screened, and so on. Additional benefits are listed in US Pat. No. 7,578,394. Centering material flows on the screen assembly 10 prevents material from falling off the screen surface and potentially contaminating previously separated materials and/or creating maintenance problems. With large volumes of material flow, the sieve assembly 10 may be under greater compression, which increases the arc of the sieve assembly 10. The larger the arc in the sieve assembly 10, the greater its ability to hold material at the sieve assembly 10 and prevent leakage of material from the edges of the sieve assembly 10 The screen assembly 10 may also be configured to deform under compression into a convex shape, or to remain substantially flat when compressed or pressed. The inclusion of connecting rods 12 in the sieve assembly 10 allows you to distribute the compression load from the vibrating screen over the sieve assembly 10. The sieve assembly 10 may have guide recesses in the connecting strips 12 to help guide the sieve assembly 10 to the desired position when installed on a vibrating screen having guides. Alternatively, the screen assembly may be mounted on a vibrating screen without connecting bars 12. In an alternative embodiment, guide recesses may be included in the sub-grid modules. US Patent Application No. 12/460200 (currently US Pat. No. 8,443,984) is incorporated herein by reference, and any embodiments disclosed therein may be incorporated into the embodiments of the present invention disclosed herein.

In FIG. 2 shows a screen element 16 having substantially parallel screen element end portions 20 and substantially parallel screen element side portions 22 that are substantially perpendicular to the screen element end portions 20. The screening surface 13 of the sieve element includes surface elements 84 running parallel to the end portions 20 of the sieve element and forming the screening openings 86. Consider FIG. 2D. The surface features 84 have a thickness T which may vary depending on the screening application and the configuration of the screen holes 86. T can be, for example, from about 43 to about 1000 microns depending on the required screening area and the width W of the screen holes 86. Screen holes 86 are elongated slits having a length L and a width W, which may vary for the selected configuration. The width may be a distance of from about 43 to about 2000 microns between the inner surfaces of each element 84 of the screen surface. The screen holes do not need to be rectangular, but they can be injection molded thermoplastic with any geometric shape suitable for a particular screening application, including approximately square, round and/or oval. To increase stability, the screen surface elements 84 may contain constituent fibrous materials that may run substantially parallel to the end portions 20. The fiber may be aramid fiber (or individual filaments thereof), natural fiber, or other material having relatively high strength. for stretching. US Patent No. 4,819,809 and US Patent Application No. 12/763,046 (currently US Patent No. 8,584,866) are incorporated herein by reference, and if necessary, the embodiments disclosed therein may be included in the sieve assemblies disclosed herein.

- 21 039521

The screen element 16 may include mounting holes 24 configured such that the elongated subgrid fasteners 44 may pass through the mounting holes 24. the surface of the sieve element will be melted, fastening the sieve element 16 to the subgrid. Alternatively, the mounting holes 24 may be provided without a tapered channel, which allows, when the portion of the elongated fastener 44 above the screening surface of the sieve element is melted, to form a shoulder on the screening surface of the sieve element, attaching the sieve element to the subgrid. The sieve element 16 may be a single injection molded thermoplastic piece. The sieve element 16 may also be a plurality of injection-molded thermoplastic pieces, each of which is configured to enclose one or more lattice openings. The use of small, injection-molded thermoplastic sieve elements 16 that are attached to a lattice frame, as disclosed herein, provides significant advantages over prior art sieve assemblies. Injection molded thermoplastic sieve elements 16 provide a width W of the screen openings 86 of up to about 43 µm. This ensures accurate and efficient screening. The arrangement of the sieve elements 16 on subgrids, which can also be injection molded from thermoplastic, makes it easy to create finished sieve assemblies with very fine screening openings. The arrangement of the sieve elements 16 on the sub-arrays also allows for significant changes in the overall size and/or configuration of the sieve assembly 10, which can be changed by including more or less sub-arrays or differently shaped sub-arrays. In addition, a sieve assembly with multiple screen hole sizes or a gradient of screen hole sizes can be created simply by placing screen elements 16 with different screen hole sizes on the sub-grids and connecting the sub-grids in the required configuration.

In FIG. 2B and 2C show the bottom of a screen element 16 having a first screen element support 28 extending between the end portions 20 and substantially perpendicular to the end portions 20. FIG. 2B also shows a second screen element support 30 orthogonal to the first screen element support 28 extending between the side edge portions 22 approximately parallel to the end portions 20 and substantially perpendicular to the side portions 22. The screen element may further include a first group of reinforcing elements. 32 substantially parallel to the side edge portions 22 and a second group of reinforcing elements 34 substantially parallel to the end portions 20. the group of reinforcing elements 32 and the second group of reinforcing elements 34 structurally stabilize the elements 84 of the screening surface and the screening holes 86 under various loads, including distribution of compressive force and/or vibration load conditions.

In FIG. 3 and 3A show the end sublattice module 14.

The end sublattice module 14 includes parallel end elements 36 of the sublattice, parallel side elements 38 of the sublattice, essentially perpendicular to the end elements of the sublattice 36. The end sublattice module 14 has locking means along one end element 36 of the sublattice and along the side elements 38 of the sublattice. The locking means may be snaps 42 and snap holes 40 so that a plurality of subgrid modules 14 can be securely connected together. The subgrid modules can be fastened together along their respective side members 38 by inserting the latch 42 into the latch hole 40 until the protruding members of the latch 42 pass through the latch hole 40 and the side member 38 of the sublattice. As the latch 42 is inserted into the latch hole 40, the protruding elements of the latch will slide together until the latch portion of each protruding element extends beyond the side sublattice element 38, engaging the interior of the side sublattice element 38. When the snap portions engage the snap hole, the side subgrid members of the two separate subgrids will be positioned side by side and fastened together. The sublattices can be separated by applying force to the protruding elements of the latch, so that the protruding elements move together, allowing the parts of the latch to exit the latch hole. Alternatively, latches 42 and latch holes 40 may be used to attach the end member 36 of a sub-array to the end member of another sub-array, such as a central sub-array (FIG. 4). The end subgrid may have an end subgrid element 36 that does not have fasteners. While the fasteners shown in the drawings are latches and latch holes, alternative means of fastening and alternative forms of latches and holes may be used, including other mechanical devices, adhesives, and the like.

Making the screen frame from subgrids, which can be substantially rigid, creates a strong and durable screen frame and screen assembly 10. The screen assembly 10 is designed in such a way that it can withstand heavy loads without damaging the screening surface and

- 22 039521 support structure. For example, the pyramid-shaped lattice frames shown in FIG. 22 and 23 provide a very strong pyramid base frame that supports individual very fine screening elements with screening openings up to 43 µm. Unlike the embodiment of the pyramidal sieve assembly of the present invention disclosed herein, existing pleated or pyramidal type wire mesh sieve assemblies are highly susceptible to damage and/or deformation under heavy load. Thus, unlike currently used sieves, the present invention provides sieve assemblies having very small and very accurate screening openings, while providing significant structural stability and resistance to damage, thereby maintaining screening accuracy under various loads. The implementation of the lattice frame from subgrids also allows you to significantly change the size, shape and/or configuration of the sieve assembly by simply changing the number and/or type of subgrids used to make the lattice frame.

The end sublattice module 14 includes a first sublattice support element 46 running parallel to the side sublattice elements 38 and a second sublattice support element 48 perpendicular to the first sublattice element 46 and perpendicular to the side sublattice elements 38. The elongated fasteners 44 may be made to mate with the fastening holes 24 of the sieve element. The sieve element 16 can be attached to the subgrid 14 by mating the elongated fasteners 44 with the fastening holes 24 of the sieve element. The portion of the elongated fastener 44 may protrude slightly above the screening surface of the sieve element when attaching the sieve element 16 to the end subgrid 14. be melted and can fill the cone-shaped channel. Alternatively, the sieve element mounting holes 24 may not have a tapered channel, while the portion of the elongated fasteners extending over the screening surface of the sieve element 16 may be configured to form a shoulder on the screening surface when melted. See fig. 34 and 35. Once attached, the screen element 16 will enclose at least one screen opening 50. Materials passing through the screen openings 86 will pass through the screen opening 50. The arrangement of the elongated fasteners 44 and the corresponding arrangement of the fastening holes 24 of the screen element provide a guide for attaching the sieve elements 16 to the subgrids, facilitating the installation of the subgrids. The elongated fasteners 44 extend through the fastening holes 24 of the sieve element, guiding the sieve element into its proper position on the surface of the subgrid. Fastening with the help of elongated fasteners 44 and fastening holes 24 of the sieve elements additionally ensures reliable attachment to the subgrid and strengthens the screening surface of the sieve assembly 10.

In FIG. 4 shows the central subgrid 18. As shown in FIG. 1 and 1A, the central sub-grid 18 may be incorporated into the sieve assembly. The central sublattice 18 has latches 42 and latch holes 40 on both end elements 36 of the sublattice. The end sublattice 14 has latches 42 and latch holes 40 on only one of the two end elements 36 of the sublattice. The center sub-grids 18 can be attached to other sub-grids at each of their end sub-grid members and side sub-grid members.

In FIG. 5 shows a plan view of the connection bar 12. FIG. 5A shows a bottom view of the tie bar 12. The tie bars 12 include latches 42 and latch holes 40 so that the tie bar 12 can be attached to the side of the screen assembly (see FIG. 9). As with the subgrids, the locking means on the connecting bar 12 are shown as latches and latch holes, but other locking means may be used to interact with the locking means of the subgrids. Handles can be attached to the connecting bars 12 (see, for example, FIG. 7) which can facilitate transportation and installation of the screen assembly. Labels and/or labels may also be attached to the connecting strips. As discussed above, the connecting bars 12 can increase the stability of the screen frame and can distribute the compression loads of the vibrating screen if the screen assembly is subjected to compression, as disclosed in US Patent No. 7,578,394 and US Patent Application No. ).

Screen elements, screen assemblies, and parts thereof, including connectors/fixings, as disclosed herein, may include dispersed nanomaterial to improve strength, durability, and other benefits associated with the use of a particular nanomaterial or a combination of different nanomaterials. Any suitable nanomaterial may be used, including, but not limited to, nanotubes, nanofibers, and/or elastomeric nanocomposites. The nanomaterial can be dispersed in the sieve elements and sieve assemblies and their parts in various percentages depending on the desired properties of the final product. For example, specific percentages may be included to increase the strength of the element or to provide wear resistance to the screening surface. Use of thermoplastic material

- 23 039521 for injection molding with nanomaterials dispersed in it can provide increased strength while using less material. Thus, structural elements, including subgrid frame supports and screen element support elements, can be made smaller, stronger and/or lighter. This is especially useful when making relatively small individual components that are built into a finished screen assembly. In addition, instead of creating separate sublattices that are bonded to each other, one large lattice structure containing nanomaterials dispersed therein can be made, which is relatively light and strong. The individual sieve elements, with or without nanomaterials, can then be attached to a single finished grid frame structure. The use of nanomaterials in the sieve element will provide increased strength while reducing the weight and size of the element. This can be especially useful when the injection molded screen elements have very small openings, as the openings are supported by the surrounding materials/elements. Another benefit of incorporating nanomaterials into sieve elements is an improved screening surface that is durable and resistant to wear. Screen surfaces tend to wear under heavy use and exposure to abrasive materials, and the use of a thermoplastic and/or thermoplastic containing abrasion-resistant nanomaterials provides the screen surface with a long service life.

In FIG. 6 shows a sub-assembly 15 of a series of sub-array modules. In FIG. 6A is an exploded view of the subassembly of FIG. 6 showing the individual sublattices and the direction of attachment to each other. The subassembly includes two modules 14 of end sublattices and three modules 18 of central sublattices. The end sub-lattice modules 14 form the ends of the sub-assembly, while the center sub-lattice modules 18 are used to fasten two end sub-lattice modules 14 through a connection between the latches 42 and the latch holes 40. The sub-lattice modules shown in FIG. 6 shown with sieve elements 16 attached. When fabricating a screen assembly from sub-assemblies with sub-grids, each sub-array can be made to a selected specification and the sieve assembly can be made from multiple sub-grids in the configurations required for the screening application. The sieve assembly can be quickly and easily assembled and will have accurate screening capabilities and significant load pressure stability. Due to the design of the screen frame and sieve elements 16, the configuration of the plurality of individual sieve elements that form the screening surface of the sieve assembly 10, and the fact that the sieve elements 16 are injection molded from thermoplastic, the openings in the sieve elements 16 are relatively stable and retain their dimensions. for optimal screening under a variety of loading conditions, including compressive loads and deflection and deflection tension.

In FIG. 7 shows a sieve assembly 10 with connecting bars 12 having handles attached to them. The sieve assembly is made of a plurality of subgrid modules attached to each other. The subgrid modules have sieve elements 16 attached to their top surfaces. In FIG. 7A is a cross-sectional section A-A of FIG. 7 where the individual subgrids can be seen attached to the sieve elements forming the screening surface. As shown in FIG. 7A, the subgrids may have subgrid support members 48 configured such that the screen assembly has a slightly concave shape when the subgrid support members 48 are secured to each other by latches 42 and latch holes 40. Since the screen assembly is mounted with a slightly concave shape, it can be deform to the desired concavity when a compressive load is applied without the need to give the sieve assembly a concave shape. Alternatively, the subgrids may be configured to provide a slightly convex sieve assembly or a substantially flat sieve assembly.

In FIG. 8 shows a top isometric view of a sieve assembly partially covered with screen elements 16. This drawing shows end subarray modules 14 and central subarray modules 18 bonded to form a sieve assembly. The screening surface can be completed by attaching the screen elements 16 to the uncoated subgrid modules shown in the drawing. The sieve elements 16 can be attached to the individual sub-grids prior to the formation of the lattice frame, or attached to the sub-grids after the sub-grids have been bonded to each other to form the lattice frame.

In FIG. 9 is an exploded isometric view of the sieve assembly shown in FIG. 1. This drawing shows eleven sub-assemblies attached to each other with latches and latch holes along the sub-array end members of the sub-array modules in each sub-assembly. Each subnode has two modules 14 end sublattices and three modules 18 central sublattices. Connecting strips 12 are attached to each side of the node. Different sizes of sieve nodes can be created using a different number of subnodes or a different number of central subgrid modules in each subnode. The assembled sieve assembly has a continuous screening surface of the sieve assembly, consisting of a plurality of screening surfaces of the sieve elements.

In FIG. 10 and 10A show the attachment of sieve elements 16 to the end subgrid module 14 according to one exemplary embodiment of the present invention. Sieve elements

- 24 039521 cops 16 can be aligned with the end sublattice module 14 using elongated fasteners 44 and fastening holes 24 of the sieve element in such a way that the elongated elements 20 of fastening 44 pass through the fastening holes 24 of the sieve element and slightly go beyond the screening surface of the sieve element . The elongated fasteners 44 can be melted to fill the tapered channels of the sieve element mounting holes 24, or alternatively form ribs on the screening surface of the sieve element, attaching the sieve element 16 to the subgrid module 14. Attaching with oblong fasteners 44 and fastening holes 24 sieve elements is only one of the embodiments of the present invention. Alternatively, the sieve element 16 may be attached to the end subgrid module 14 with adhesive, retainers and fixing holes, laser welding, etc. Although two screen elements are shown for each subarray, the present invention includes alternative configurations with one screen element per subarray, multiple screen elements per subarray, one screen element per subarray opening, or one screen element covering multiple subarrays. End subgrid 14 may be substantially rigid and may be formed as a single injection molded thermoplastic piece.

In FIG. 10 is a plan view of the end sublattice module shown in FIG. 10A with sieve elements 16 attached to the end subgrid. In FIG. 10C is a section B-B of the end sublattice of FIG. 10A. The sieve element 16 is placed on the end sublattice module in such a way that the elongated fastener 44 passes through the fastening hole and extends beyond the screening surface of the sieve element. The portion of the elongated fastener 44 passing through the fastening hole and extending beyond the screening surface of the sieve element can be melted to attach the sieve element 16 to the end subgrid module, as discussed above.

In FIG. 11 and 11A illustrate the attachment of sieve elements 16 to the central subgrid module 18 in accordance with one exemplary embodiment of the present invention. The screen elements 16 can be aligned with the central sublattice module 18 by means of the elongated fasteners 44 and the fastening holes 24 of the sieve element in such a way that the elongated fasteners 44 pass through the fastening holes 24 of the sieve element and slightly extend beyond the screening surface of the sieve element. The elongated fasteners 44 may be melted to fill the tapered channels of the screen element mounting holes 24, or alternatively, to create ribs on the screening surface of the screen element by attaching the screen element 16 to the central sublattice module 18. Attaching with oblong fasteners 44 and fastening holes 24 sieve elements is only one of the embodiments of the present invention. Alternatively, the sieve element 16 can be attached to the central subgrid module 18 with adhesive, retainers and fixing holes, laser welding, etc. Although two screen elements are shown for each subarray, the present invention includes alternative configurations with one screen element per subarray, multiple screen elements per subarray, one screen element per subarray opening, or one screen element covering multiple subarrays. The central subgrid 18 may be substantially rigid and may be formed as a single injection molded thermoplastic piece.

In FIG. 12 and 12A show screen assemblies 10 mounted on a vibrating screen having two screening surfaces. The vibrating screen may have compression units on the side members of the vibrating screen as disclosed in US Pat. The underside of the screen assembly may mate with the mating face of the vibrating screen assembly as disclosed in US Pat. No. 7,578,394 and US Pat. The vibrating screen may include a central wall element configured to receive a connecting bar of a side element of the screen assembly opposite the side element of the screen assembly receiving compression. The central wall element may be angled so that the compressive force acting on the sieve assembly deflects the sieve assembly downward. The sieve assembly can be installed in the vibrating screen in such a way that it is able to receive the material to be screened. The screen assembly may include guide recesses configured to mate with the vibrating screen tracks so that the screen assembly can be guided into place during installation, and may include guide module configurations as disclosed in US Patent Application No. 12/460,200 (currently US Pat. No. 8,443,984).

In FIG. 12B is a front view of the vibrating screen of FIG. 12. In FIG. 12B shows the screen assemblies 10 mounted on a vibrating screen with compression applied to deflect the screen assemblies downward into a concave shape. Alternatively, the sieve assembly may be preformed to a predetermined concave shape without compressive force.

- 25 039521

In FIG. 13 and 13A show the installation of the sieve assembly 10 in a vibrating screen with one screening surface. The vibrating screen may have a compression unit on the side element of the vibrating screen. The sieve assembly 10 can be placed in a vibrating screen as shown in the drawing. A compressive force may be applied to the link bar or to the side member of the screen assembly so that the screen assembly deflects downward into a concave shape. The underside of the screen assembly may mate with the mating face of the vibrating screen assembly as disclosed in US Pat. No. 7,578,394 and US Pat. The vibrating screen may include a side element wall opposite the compression unit, configured to receive a connecting bar or a side element of the sieve assembly. The wall of the side member may be angled so that the compressive force acting on the sieve assembly deflects the sieve assembly downward. The sieve assembly can be installed in the vibrating screen in such a way that it is able to receive material to be screened. The screen assembly may include guide recesses configured to mate with the vibrating screen guides so that the screen assembly can be guided into place during installation.

In FIG. 14 is a front view of screen assemblies 52 mounted on a vibrating screen with two screens, in accordance with one exemplary embodiment of the present invention. The sieve assembly 52 is an alternative embodiment in which the sieve assembly was already ready to be installed in the vibrating screen without applying a load to the sieve assembly, i. e. the screen assembly 52 includes a bottom portion 52A which is configured to mate with the bed 83 of the vibrating screen. The bottom portion 52A may be integral with the screen assembly 52 or may be a separate piece. The screen assembly 52 includes structural elements similar to the screen assembly 10, including subgrids and screen elements, but also includes a bottom portion 52A that allows it to fit against the bed 83 without being compressed to acquire a concave shape. The screening surface of the sieve assembly 52 may be substantially flat, concave or convex. The screen assembly 52 can be held in position by applying a compressive force to the side member of the screen assembly 52. The bottom of the screen assembly 52 may be preconfigured to mate with any type of vibrating screen mating surface.

In FIG. 15 is a front view of a screen assembly 53 mounted on a single screen vibrating screen, in accordance with one exemplary embodiment of the present invention. The sieve assembly 53 has structural elements similar to the sieve assembly 52 disclosed above, including a bottom portion 53A which is configured to mate with the bed 87 of the vibrating screen.

In FIG. 16 shows the end subassembly of the support frame, and FIG. 16A is an exploded view of the end subassembly of the support frame of FIG. 16. The support frame end subassembly shown in FIG. 16 includes eleven modules 14 of end subgrids. Alternative configurations may be used having more or fewer end modules of the sublattices. Modules 14 of the end sublattices are attached to each other by means of latches 42 and latch holes 40 along the side elements of the modules 14 of the end sublattices. In FIG. 16A shows the attachment of the individual modules of the end sub-grids in such a way that an end sub-assembly of the support frame is obtained. As shown, the end subassembly of the support frame is covered with sieve elements 16. Alternatively, the end subassembly of the support frame may be made of end subgrids before the screen elements are attached, or partly from pre-coated subgrid modules and partly from uncoated subgrid modules.

In FIG. 17 shows the central sub-assembly of the support frame 17, and FIG. 17A is an exploded view of the central subassembly of the support frame of FIG. 17. The central support frame subassembly shown in FIG. 17 includes eleven modules 18 of the central sublattices. Alternative configurations may be used having more or fewer end modules of the sublattices. The modules 18 of the central sublattices are attached to each other by means of latches 42 and latch holes 40 along the side elements of the modules 18 of the central sublattices. In FIG. 17A shows the attachment of individual modules of the central sub-grids in such a way that a central support frame sub-assembly is obtained. As shown, the center subassembly of the support frame is covered with sieve elements 16. Alternatively, the center subassembly of the support frame may be formed from center subgrids before the screen elements are attached, or partly from pre-coated subgrid modules and partly from uncoated subgrid modules.

In FIG. 18 is an exploded view of a screen assembly comprising three center support frame subassemblies and two end support frame subassemblies. The nodes of the support frame are attached to each other by means of latches 42 and latch holes 40 on the end elements of the subgrids. Each module of the central sublattice is attached to two other modules of the sublattice using end elements. The end elements 36 of the modules of the end sublattices, which do not have latches 42 or latch holes 40, form the end edges of the sieve assembly. The sieve assembly may be provided with more or fewer central support frame subassemblies, or with larger or smaller frame subassemblies. Connecting strips can be added to the side edges of the sieve assembly. As shown, sieve assembly

- 26 039521 has sieve elements installed on subgrid modules before installation. Alternatively, the screen elements 16 may be installed after all or part of the installation.

In FIG. 19 shows an alternative embodiment of the present invention where the sieve assembly 54 is substantially flat. The screen assembly 54 may be flexible such that it may deform into a concave or convex shape, or may be substantially rigid. The sieve assembly 54 can be used with a flat screening surface. See fig. 39. As shown, screen assembly 54 has connecting bars 12 attached to the sides of screen assembly 54. Screen assembly 54 may be configured with various embodiments of the lattice structures and screen elements disclosed herein.

In FIG. 20 shows an alternative embodiment of the present invention in which the sieve assembly 56 is convex. The screen assembly 56 may be flexible such that it may deform into a more convex shape, or may be substantially rigid. As shown, the sieve assembly 56 has connecting bars 12 attached to the sides of the sieve assembly. The sieve assembly 56 may be configured with various embodiments of the lattice structures and sieve elements disclosed herein.

In alternative embodiments of the present invention, a sieve assembly 410 is provided having sieve elements 416, center subarray modules 418, and end subarray modules 414. See, for example, FIG. 47. The sieve element 416 may be injection molded from a thermoplastic and may have all of the structural elements of the sieve element 16 disclosed above. The sieve element 416 may be incorporated into any of the sieve assemblies disclosed herein (for example, sieve assemblies 10 and 52-54 shown in FIGS. 1, 14, 15, and 19, respectively) and is interchangeable with the sieve element 16. The sieve element 416 may include positioning holes 424, which may be located in the center of the sieve element 416 and in each of the four corners of the sieve element 416. See, for example, FIG. 48 and 48A. The sieve element 416 may have more or fewer positioning holes 424, and may be provided in many configurations. The positioning holes 424 may be substantially the same as the mounting holes 24 and may be used to position the screen element 416 on the subgrid. Alternatively, the screen element 416 may be positioned without positioning holes 424. The screen element 416 may include a plurality of tapered channels 470 that may facilitate removal of the screen element 416 from a mold, which mold may have ejector pins configured to eject the screen element from the mold. . See, for example, FIG. 48 and 48A.

On the underside of the screen element 416, a first adhesive means may be provided, which may be a plurality of protrusions, cavities, or a combination of protrusions and cavities. The first adhesive of the sieve element 416 may be configured to mate with a complementary second adhesive on the top surface of the subarray module. For example, in FIG. 48B and 48C, a plurality of hollow pockets 472 are provided. A plurality of hollow pockets 472 may be located along the end portions 20 and side portions 22 between the positioning holes 424. Additional hollow pockets 272 may be located along all or part of the first support element 28 of the sieve element, or along all or part of the second support element 30 sieve element. Although hollow pockets 472 are shown as elongated cavities, they can be of various configurations, sizes, and depths. In addition, the first adhesive means on the sieve element 416 may be protrusions rather than cavities. The first adhesive of the sieve element 416 may be configured to mate with a complementary second adhesive on the sub-array module such that a portion of the sieve element 416 overlaps at least a portion of the sub-array module, regardless of whether the sieve element 416 or the sub-array module has projections or cavities.

An end subgrid module 414 and a central subgrid module 418 may be included in the sieve assembly 410. See, for example, FIG. 49, 49A, 50 and 50A. The end sublattice module 414 and the central sublattice module 418 may be injection molded from a thermoplastic and may include all of the structural elements of the end sublattice module 14 and the central sublattice module 18 disclosed above. The end sublattice module 414 and the central sublattice module 418 may be used interchangeably wherever an end sublattice module 14 and a central sublattice module 18 are specified. The end sublattice module 414 and the central sublattice module 418 may have a plurality of elongated positioning elements 444, which may be substantially the same as the fasteners 44. elements 416 may be located on the end sublattice module 414 and the central sublattice module 418.

The end sublattice module 414 and the central sublattice module 418 may include a second adhesive means on the upper surface of each of the end sublattice module 414 and the central sublattice module 418, wherein the second adhesive means may be complementary to the first adhesive means of the sieve element 416 so that the sieve element could be connected to the sublattice module by mating the first and second adhesive means. In one embodiment of the present invention, the second adhesive means may be a plurality of fusible rods 476 located along the upper surface of the side elements 38 of the sublattice and the end elements 36 of the sublattice. The end sublattice module 414 and the central sublattice module 418 may also include a plurality of fusible rods 478, which can be shortened fusible rods having a height that is less than the height of the fusible rods 476 located along the upper surface of the first sublattice support element 46 and the second support element 48 sublattices. See, for example, in FIG. 49, 50. Although shown as elongated protrusions, fusible rods 476 (and 478) can be of various shapes and sizes and can be arranged in various configurations. Alternatively, the second adhesive means may be cavities, pockets, or the like, and may be configured to receive protrusions from the screen element. The second adhesive means may include both protrusions and cavities.

Each of the plurality of hollow pockets 472 is configured to receive fusible rods 476 and shortened fusible rods 478 located on subgrids (414, 418, 458 and 460). See, for example, FIG. 45A-45E and 46. As shown in FIG. 45B-45E, the fusible rods 476 enter the plurality of hollow pockets 472 when the screen element 416 is placed on the subgrid. The hollow pockets 472 may have a width C that is slightly greater than the width D of the fusible rod 476. The hollow pocket 472 may have a depth A that is slightly less than the height B of the fusible rod 476. See, for example, FIG. 47. Height B of fusible rod 476 may be approximately 0.056 inches (~1.42 mm). Prior to melting the fusible rods 476, the screen element 416 can rest on the fusible rods 476 without contact with the rest of the subgrid. The sieve element 416 and the subgrids can be connected to each other by laser welding. The connection can be made by chemical bonding between hollow pockets 472 and fusible rods (476 or 478) or by melting parts of the material of each component so that the components solidify together. In one embodiment, when the screen element 416 is located on the subgrid, the fusible rod 476 (or shortened fusible rod 478) can be melted, which allows the melted portion of the fusible rod 476 to fill all or part of the width C of the hollow pocket 472. In some embodiments, the implementation can be melted about 0.006 inches (~0.15 mm) of fusible rod 476 and fill all or part of the width C of hollow pocket 472. Melting of fusible rod 476 can be performed using laser welding, which can attach the sieve element 416 to the subgrid. Laser 500 can be configured and controlled to achieve a specific depth of fusible rod 476.

Fusible rods 476 (or shortened fusible rods 478) may contain carbon, graphite, or other materials capable of responding to a particular laser wavelength. Fusible rods can additionally be made to match the laser used for laser welding. The fusible rods may have a specific length to suit the laser 500. Although shown as elongated protrusions, other shapes and/or designs may be provided for the fusible rods depending on the requirements of the selected laser. In embodiments having fusible bars on the subgrids, the screen elements 416 typically do not contain carbon or graphite. The sieve element 416 and the fusible rods can be made of different materials so that the selected laser 500 can pass through the sieve element 416 without melting it and contact the fusible rods. See, for example, FIG. 45B and C. Screen element 416 may be made of TPU or a similar material having the performance required for the screening application. The sieve element 416 may be substantially transparent. The subgrids (414 and 418) may be made of nylon or similar materials. The fusible rods may have a higher melting point than the material of the sieve element 416, so that when the fusible rods melt, the portion of the sieve element 416 also melts, which can be achieved by transferring heat from the molten portion of the fusible rod 476, which contacts the sieve element 416 in hollow pocket 472. Thus, the sieve element 416 will be welded to the subgrid. See, for example, FIG. 51, 51A, 52 and 52A.

Laser welding is usually performed by focusing the laser beam in the direction of the seam or the area of material transformation from a solid state to a liquid state, and after the removal of the laser beam, the material returns to the solid state. Laser welding is a type of fusion welding that can be realized by conduction or penetration. Conductive welding relies on the conductivity of the material being welded to generate heat and melt the material. Laser welding of the sieve element 416 to the fusible rod sublattice involves laser welding two different materials together. This is generally not possible with laser welding; however, application of the laser 500 through the sieve element 416 to the fusible rods, which have conductive properties to generate heat using the selected laser 500, causes the fusible rods (476 or 478) to melt. Similarly, heat generated by conduction and/or from molten

- 28 039521 fusible rod material, causes melting of the sieve element area. The two liquid materials combine and create a strong solid connection between the sublattice and the sieve element when the laser is retracted and the combined materials return to the solid state. By forming laser welded joints between the sieve element and the subgrids, the connection between the components is very strong, which is necessary for the sieve assembly components used in vibrating screens. Screen assemblies can be subjected to vibration forces in excess of 8 gauss, abrasives and chemicals, and very high load requirements. Therefore, sieve units must be very strong and durable. Embodiments of the present invention provide sieve assemblies made from a plurality of pieces fastened together. The creation of screen assemblies from smaller parts allows micro-injection molding of screen elements with very small openings, for example, having a thickness of from about 43 to about 100 microns. The strength of laser welding increases the overall strength of the screen assemblies, which provides the benefits of micro-injection molding of the screen elements while maintaining the wear resistance of the screen assemblies. Laser welding also provides a more efficient bonding procedure compared to other bonding procedures such as heat bonding. In some embodiments, laser welding can be completed within about 8-10 seconds, while heat bonding, affecting other embodiments, can take about 1.5 minutes.

The end sublattice module 414 (or 14) and the central sublattice module 418 (or 18) may include a secondary support frame 488 enclosing the lattice holes 50. The secondary support frame 488 may encompass all or only a portion of the lattice openings 50. The secondary support frame 488 increases the strength and durability of the end sublattice module 414 (or 14) and the central sublattice module 418 (or 18). The secondary support frame 488 adds to the overall strength of the sieve assembly 410, allowing it to withstand vibration forces in excess of 8 gauss.

In FIG. 21 and 21A show an alternative embodiment of the present invention incorporating pyramidal shaped sublattice modules. The screen assembly is shown with connecting bars 12 attached. The screen assembly includes center and end subarray modules 14 and 18 (or 414 and 418) and pyramidal center and end subarray modules 58 and 60 (or 458 and 460). By incorporating modules 58 and 60 of pyramid-shaped subgrids into the sieve assembly, an increased screening surface can be obtained. In addition, the screened material can be controlled and guided. The sieve assembly can be concave, convex or flat. The sieve assembly may be flexible and may deform into a concave or convex shape when a compressive force is applied. The screen assembly may include guide recesses capable of mating with guide mating surfaces on the vibrating screen. Various configurations of subgrid modules and pyramidal subgrid modules can be used which can increase or decrease screening surface area and material flow characteristics. Unlike cellular screens or similar technology, which may include corrugations or other means to increase surface area, the screen assembly shown is supported by a screen frame, which may be substantially rigid and capable of withstanding significant loads without damage or failure. At high material flows, traditional screen assemblies with corrugated screening surfaces are often flattened or damaged by the weight of the material, which affects performance and reduces the screening surface area of such screen assemblies. The screen assemblies disclosed herein are difficult to damage due to the strength of the lattice frame, while the benefits of the increased surface area provided by the inclusion of pyramidal shaped sub-arrays can be maintained under significant loads.

The pyramidal end sublattice 58 is shown in FIG. 22 and 22A. The pyramidal end sublattice 58 includes a first and a second lattice frame forming lattice openings 74 of the first and second inclined surface. The pyramidal end sub-array 58 includes a ridge portion 66, sub-array side members/base members 64, and first and second sloped surfaces 70 and 72, respectively, which peak at the ridge portion 66 and extend down to the lateral member 64. The sub-arbors 58 and 60 are pyramidal in shape and have triangular end members 62 and triangular middle support members 76. The slope angles of the first and second ramps 70 and 72 shown are exemplary only. Various angles can be used to increase or decrease the surface area of the screening surface. The pyramidal end sub-array 58 has locking means along the side members 64 and on at least one triangular end member 62. The locking means may be latches 42 and latch holes 40 to allow a plurality of sub-array modules 58 to be fastened together. Alternatively, the latches 42 and the latch holes 40 may be used to secure the pyramidal end sublattice 58 to the end sublattice 14, the central sublattice 18, or the pyramidal central sublattice 60. On the first and second inclined surfaces 70 and 72, elongated fasteners 44 can be made, mating with mounting holes

- 29 039521 with 24 sieve elements. The sieve element 16 can be attached to the pyramidal end sublattice 58 by mating the elongated fasteners 44 with the fastening holes 24 of the sieve element. Part of the elongated fastening element 44 may slightly protrude above the screening surface of the sieve element when the sieve element 16 is attached to the end sub-grid 58 of a pyramidal shape. The sieve element mounting holes 24 may include a cone-shaped channel so that the portion of the elongated fasteners 44 that extends above the screening surface of the sieve element can be melted and fill the cone-shaped channel. Alternatively, the sieve element mounting holes 24 may not have a tapered channel, whereby the portion of the elongated fasteners that extends over the screening surface of the sieve element 16 may be melted to form a bead on the screening surface. Once attached, the screen element 16 may surround the first and second inclined screen holes 74. Materials passing through the screen holes 86 will pass through the first and second screen holes 74.

The central sublattice 60 is pyramidal in shape, as shown in FIG. 23 and 23A. The pyramid-shaped central sublattice 60 includes a first and a second lattice frame forming lattice openings 74 of the first and second inclined surface. The pyramid-shaped central sub-array 58 includes a ridge portion 66, sub-array side members/base members 64, and first and second sloped surfaces 70 and 72 that peak on the ridge portion 66 and extend down to the lateral member 64. Sub-arrays 58 and 60 pyramidal shape have triangular end elements 62 and triangular middle elements 76. The angles of inclination of the first and second inclined surfaces 70 and 72 shown are exemplary only. Various angles can be used to increase or decrease the surface area of the screening surface. The pyramidal-shaped central sublattice 58 has locking means along the side members 64 and at least on both triangular end members 62. The locking means may be latches 42 and latch holes 40 to allow a plurality of center sublattice modules 60 to be fastened together. Alternatively, the latches 42 and the latch holes 40 may be used to secure the pyramid-shaped central sub-array 58 to the pyramid-shaped end sub-array 14, central sub-arbor 18, or pyramid-shaped end sub-arbor 58. On the first and second inclined surfaces 70 and 72, elongated fasteners 44 may be provided to mate with the fastening holes 24 of the sieve element. The sieve element 16 can be attached to the pyramidal-shaped central sublattice 60 by mating the elongated fasteners 44 with the fastening holes 24 of the sieve element. Part of the elongated fastening element 44 may slightly protrude above the screening surface of the sieve element when the sieve element 16 is attached to the central sub-grid 58 of the pyramidal shape. The sieve element mounting holes 24 may include a cone-shaped channel so that the portion of the elongated fasteners 44 that extends above the screening surface of the sieve element can be melted and can fill the cone-shaped channel. Alternatively, the sieve element mounting holes 24 may not have a tapered channel, whereby that portion of the elongated fasteners that extends over the screening surface of the sieve element 16 may be melted to form a bead on the screening surface. Once attached, the screen element 16 may enclose the inclined screen opening 74. Materials passing through the screen openings 86 will pass through the screen opening 74. Although pyramidal and flat shaped screen structures are shown, it will be appreciated that variously shaped sub-screens and corresponding screen elements can be made in accordance with the present invention.

In FIG. 24 shows a sub-assembly of a series of pyramid-shaped sub-array modules. In FIG. 24A is an exploded view of the sieve assembly of FIG. 24, which shows the individual pyramid-shaped sublattices and the mounting direction. The sub-assembly includes two pyramidal-shaped end sublattices 58 and three pyramidal-shaped central sublattices 60. Pyramidal end sub-lattices 58 form the ends of the subassembly, while pyramid-shaped center sub-lattices 60 are used to connect two end sub-lattices 58 via a connection between latches 42 and latch holes 40. The pyramidal sub-lattices shown in FIG. 24 shown with sieve elements 16 attached. Alternatively, the subassembly may be made from sub-arrays before the sieve elements are attached, or partly from pre-coated pyramid-shaped sub-array modules and partly from uncoated pyramid-shaped sub-array modules.

In FIG. 24B and 24C show the attachment of sieve elements 16 to a pyramid-shaped end sub-grid 58 in accordance with one exemplary embodiment of the present invention. The sieve elements 16 can be aligned with the end sublattice 58 of a pyramidal shape using elongated fasteners 44 and fastening holes 24 of the sieve element so that the elongated fasteners 44 passing through the fastening holes 24 of the sieve element can slightly extend beyond the screening surface of the sieve element. Part of the elongated fasteners 44, extending beyond the screening surface of the sieve element, can be melted to fill the cone-shaped channels of the mounting holes 24 of the sieve

- 30 039521 element or, alternatively, for the formation of beads on the screening surface of the sieve element, attaching the sieve element 16 to the sublattice 58 of a pyramidal shape. Attachment by means of elongated fasteners 44 and fastening holes 24 of the sieve elements is only one embodiment of the present invention. Alternatively, the screen element 16 may be attached to the pyramid-shaped end sub-grid 58 with adhesive, retainers and retainer holes, etc. While four screen elements are shown for each pyramidal end subarray 58, the present invention includes alternative configurations with two screen elements per pyramid end subarray 58, multiple screen elements per pyramid end subarray 58, or having a single screen element covering a sloping the surface of a set of modules of pyramidal sublattices. The pyramid-shaped end subgrid 58 may be substantially rigid and may be a single thermoplastic injection molded piece.

In FIG. 24D and 24E show the attachment of sieve elements 16 to a pyramidal-shaped central sub-grid 60 in accordance with one exemplary embodiment of the present invention. The sieve elements 16 can be aligned with the pyramidal-shaped central sub-array 60 using elongated fasteners 44 and the sieve element fastening holes 24 so that the elongated fasteners 44 passing through the sieve element fastening holes 24 can slightly extend beyond the screening surface of the sieve element. The portion of the elongated fasteners 44 that extends beyond the screening surface of the sieve element can be melted to fill the tapered channels of the fastening holes 24 of the sieve element or, alternatively, to form beads on the screening surface of the sieve element, attaching the sieve element 16 to the pyramid-shaped subgrid 60. Attachment by means of elongated fasteners 44 and fastening holes 24 of the sieve elements is only one embodiment of the present invention. Alternatively, the screen element 16 may be attached to the central pyramidal sub-grid 58 with adhesive, retainers and retainer holes, etc. While four screen elements are shown for each pyramidal-shaped central sub-array 60, the present invention includes alternative configurations with two screen elements per pyramid-shaped central sub-array 60, multiple screen elements per pyramid-shaped central sub-array 60, or having one screen element covering a sloping the surface of a set of modules of pyramidal sublattices. The end subgrid 60 of the pyramidal shape may be substantially rigid and may be a single injection molded thermoplastic piece. Although pyramidal and planar lattice structures are shown, it should be understood that the sub-arrays and corresponding sieve elements can be made in various shapes in accordance with the present invention.

In FIG. 53-56A show pyramidal end and center sublattices 458 and 460, respectively, in accordance with exemplary embodiments of the present invention. The pyramidal end and center sublattices 458 and 460 may be injection molded from thermoplastic and may have all of the pyramidal end and center sublattices 58 and 60 features discussed herein above. As with the end sub-array module 414 and the central sub-array module 418, the pyramid-shaped end and center sub-arrays 458 and 460 can have positioning elements 444 corresponding to the positioning holes 424 of the sieve element 416 so that the sieve elements 416 can be placed for attachment on the end and the central sublattices 458 and 460 are pyramidal in shape. The pyramidal end and center sublattices 458 and 460 may have second adhesive means, such as a plurality of fusible rods 476 and shortened fusible rods 478. pockets. The sieve elements 416 can be laser welded to the pyramidal subgrids. The pyramid-shaped end and center sublattices 458 and 460 may include a secondary support frame 488 enclosing the lattice holes 74. The secondary support frame 488 may encompass all or only a portion of the lattice opening 74. The secondary support frame 488 enhances the strength and durability of the pyramidal end and center sublattices 458 and 460. The pyramidal end and center subgrids 458 and 460 may include a flattened ridge portion 465 and may also have fixtures 490 on the ridge 66 for welding jigs. See, for example, FIG. 53. Flattened ridge portion 465 may allow for easier molding than rounded or pointed embodiments and may allow for easier release and/or removal of sublattices from molds. Embodiments may include one or more welding jigs retainers 490 that may be used for alignment and/or assembly during laser welding. Welding guides can engage the subgrid in welding guide fixtures 490 to provide alignment for laser welding. The flattened part 465 of the ridge can provide easier engagement with the 490 clamps for the matcher.

- 31 039521 rock conductors.

In FIG. 25 is a plan view of a sieve assembly 80 having pyramid-shaped sub-arrays, which may be any of sub-arrays 14, 18, 414, and 418. As shown, sieve assembly 80 is formed from screen sub-assemblies attached to each other in alternating flat sub-assemblies and pyramid-shaped sub-assemblies. . Alternatively, the pyramidal subassemblies may be attached to each other, or fewer or more pyramidal subassemblies may be used. In FIG. 25A is a sectional C-C section of the sieve assembly of FIG. 25. As shown, the sieve assembly has five rows of pyramid-shaped sub-grid modules and six rows of flat sub-grids, with the rows of flat sub-grid modules located between the rows of pyramid shaped sub-grids. Connecting bars 12 are attached to the sieve assembly. Any combination of rows of flat subgrids and rows of pyramidal subgrids can be used. In FIG. 25B is an enlarged sectional view of FIG. 25A. In FIG. 25B, the attachment of each sub-lattice to the other sub-lattice and/or tie bar 12 is shown using latches and latch holes.

In FIG. 26 is an exploded isometric view of a sieve assembly having pyramid-shaped sublattice modules. This figure shows eleven sub-assemblies attached to each other by latches and latch holes along the sub-array side members of the sub-array modules in each sub-assembly. Each flat subassembly has two end sublattices (14 or 414) and three central sublattices (18 or 418). Each pyramid-shaped sub-assembly has two pyramid-shaped end sub-lattices (58 or 458) and three pyramid-shaped central sub-lattices (60 or 460). Connecting straps 12 are attached to each end of the assembly. Sieve nodes of different sizes can be created using a different number of subnodes or a different number of modules of the central subgrids. The screening surface area can be increased by including more pyramidal assemblies or reduced by including more flat assemblies. The assembled sieve assembly has a continuous screening surface of the sieve assembly, consisting of a plurality of screening surfaces of the sieve elements.

In FIG. 27 shows the installation of sieve units 80 on a vibrating screen having two screening surfaces. In FIG. 30 is a front view of the vibrating screen of FIG. 27. The vibrating screen may have compression units on the side members of the vibrating screen. The screen assemblies can be placed in a vibrating screen as shown in the drawing. A compressive force may be applied to the side member of the sieve assembly such that the sieve assembly is deflected downward into a concave shape. The underside of the screen assembly may mate with the mating face of the vibrating screen assembly as shown in US Pat. No. 7,578,394 and US Pat. The vibrating screen may include a central wall element configured to receive a side element of the screen assembly opposite the side element of the screen assembly receiving compression. The central wall element may be angled so that the compressive force acting on the sieve assembly deflects the sieve assembly downward. The sieve assembly can be installed in the vibrating screen in such a way that it is able to receive the material to be screened. The screen assembly may include guide recesses configured to mate with the vibrating screen guides so that the screen assembly can be guided into place during installation.

In FIG. 28 is an isometric view of a sieve assembly having pyramidal shaped sub-grids with no sieve elements attached. The sieve assembly shown in Fig. 28 is slightly concave, however, the sieve assembly may be more concave, convex, or flat. The sieve assembly may be made up of a plurality of subassemblies, which may be any combination of flat subassemblies and pyramidal shaped subassemblies. As shown, eleven sub-assemblies are provided, however, more or fewer sub-assemblies may be provided. The sieve assembly is shown without sieve elements 16 (or 416). The sub-arrays may be joined together before or after the screen elements are attached to the sub-arrays, or any combination of sub-arrays with attached screen elements and sub-arrays without screen elements can be assembled. In FIG. 29 shows the sieve assembly of FIG. 28 partially covered with sieve elements. The pyramid-shaped subassemblies include pyramid-shaped end sub-grids 58 and pyramid-shaped central sub-grids 60 . The flat sub-assemblies include flat end sub-grids 14 and flat center sub-grids 18. The sub-grid modules can be attached to each other using latches and latch holes.

In FIG. 31 shows the installation of a screen assembly 81 in a vibrating screen having a single screening surface, in accordance with an exemplary embodiment of the present invention. The sieve assembly 81 is similar in configuration to the sieve assembly 80 but includes additional pyramidal and flat assemblies. The vibrating screen may have a compression unit on the side element of the vibrating screen. Sieve node 81 may be located in the vibrating screen, as shown in the drawing. A compression force may be applied to the side member of the sieve assembly 81 such that the sieve assembly 81 deflects downward into a concave shape. The underside of the sieve assembly can mate with the mating surface of the vibrating screen sieve assembly as disclosed in the patent.

- 32 039521

US No. 7578394 and US patent application No. 12/460200 (currently - US patent No. 8443984). The vibrating screen may include a side member wall opposite the compression assembly, configured to receive a side member of the sieve assembly. The wall of the side member may be angled so that the compressive force acting on the sieve assembly deflects the sieve assembly downward. The sieve assembly can be installed in the vibrating screen in such a way that it can receive the material to be screened. The screen assembly may include guide recesses configured to mate with the vibrating screen guides so that the screen assembly can be guided into place during installation.

In FIG. 32 is a front view of screen assemblies 82 mounted on a vibrating screen having two screening surfaces, in accordance with an exemplary embodiment of the present invention. The sieve assembly 82 is an alternative embodiment in which the sieve assembly has been pre-configured to fit into a vibrating screen without applying a load to the sieve assembly, i.e. the screen assembly 82 includes a bottom portion 82A which is configured to mate with the bed 83 of the vibrating screen. The bottom portion 82A may be integrally formed with the screen assembly 82 or may be a separate piece. The screen assembly 82 has structural elements similar to the screen assembly 80, including sub-grids and screen elements, but also includes a bottom portion 82A that allows it to fit on the bed 83 without being compressed into a concave shape. The screening surface of the sieve assembly 82 may be substantially flat, concave or convex. The screen assembly 82 may be held in place by applying a compressive force to the side member of the screen assembly 82, or may simply be held in place. The lower part of the sieve assembly 82 can be pre-made with the possibility of pairing with any type of mating surface of the vibrating screen.

In FIG. 33 is a front view of a screen assembly 85 mounted on a vibrating screen having a single screening surface, in accordance with an exemplary embodiment of the present invention. The sieve assembly 85 is an alternative embodiment in which the sieve assembly has been previously configured to fit into a vibrating screen without applying a load to the sieve assembly, i.e. the sieve assembly 85 includes a bottom portion 85A that is configured to mate with the bed 87 of the vibrating screen. The bottom portion 85A may be integral with the screen assembly 85 or may be a separate piece. The screen assembly 85 has structural elements similar to the screen assembly 80, including sub-grids and screen elements, but also includes a bottom portion 85A that allows it to fit on the bed 87 without being compressed into a concave shape. The screening surface of the sieve assembly 85 may be substantially flat, concave or convex. The screen assembly 85 may be held in place by applying a compressive force to the side member of the screen assembly 85, or simply held in place. The lower part of the sieve assembly 85 can be pre-made with the possibility of pairing with any type of mating surface of the vibrating screen.

In FIG. 34 is an isometric view of the end subgrid shown in FIG. 3 having one sieve element partially attached to it. In FIG. 35 is an enlarged view of fragment E of the end sublattice shown in FIG. 34. In FIG. 34 and 35, the sieve element 16 is partially attached to the end sublattice 38. The sieve element 16 is aligned with the sublattice 38 using elongated fasteners 44 and fastening holes 24 of the sieve element in such a way that the elongated fasteners 44 pass through the fastening holes 24 of the sieve element and slightly out beyond the screening surface of the sieve element. As shown in the end edge portion of the sieve element 16, portions of the elongated fasteners 44 extending beyond the screening surface of the sieve element are melted to form beads on the screening surface of the sieve element, attaching the sieve element 16 to the end subgrid module 38.

In FIG. 36 shows a slightly concave sieve assembly 91 containing pyramid-shaped sub-grids embedded in a portion of the sieve assembly 91 in accordance with one exemplary embodiment of the present invention. The screening surface of the sieve assembly may be substantially flat, concave or convex. The sieve assembly 91 can be configured to deflect to a predetermined shape under the action of a compression force. The sieve assembly 91, as shown in FIG. 36 contains pyramid-shaped subgrids in the portion of the sieve assembly closest to the material inlet to the vibrating screen. The part, which includes pyramidal subgrids, provides an increased screening surface area and a directed material flow. Part of the sieve assembly, installed near the outlet end of the vibrating screen, contains flat subgrids. An area may be provided on the flat portion to allow drying and/or agglomeration of the material on the sieve assembly. Various combinations of flat and pyramidal subgrids can be included in the screen assembly depending on the desired configuration and/or the particular screening application. In addition, vibrating screens that use multiple screen assemblies may have separate screen assemblies in various configurations to be used together in specific applications. For example, sieve assembly 91 can be used with other sieve assemblies so that it is located near the exit end of the vibrating screen, providing a sinter

- 33 039521 and/or drying of the material.

In FIG. 37 is a block diagram showing the steps for manufacturing a sieve assembly in accordance with one exemplary embodiment of the present invention. As shown in FIG. 37, the sieve manufacturer can obtain the sieve assembly specifications for that sieve assembly. Characteristics may include at least one of the following: material requirements, screening area, throughput, and separation boundary for the sieve assembly. The manufacturer can then specify screening hole requirements (shape and size) for the screen element as disclosed herein. The manufacturer can then determine the screen configuration (eg, assembly size, screen surface shape and configuration, etc.). For example, a manufacturer may have screen elements arranged in at least one of a flat configuration and a non-flat configuration. The planar configuration can be made up of center sub-grids (18 or 418) and end sub-grids (14 or 414). The non-planar configuration may include at least a portion of the central sub-arrays (60 or 460) of a pyramidal shape and/or the end sub-arrays (58 or 458) of a pyramidal shape. The sieve elements can be obtained by injection molding. Sublattice modules can also be obtained by injection molding, but injection molding is not required. The sieve elements and sublattices may contain nanomaterial, as disclosed herein, dispersed within. Once the sieve elements and subarray modules have been created, the sieve elements can be attached to the subarray modules. The sieve elements and sub-arrays can be bonded together using bonding materials in which the nanomaterial is dispersed. The sieve elements can be attached to the subgrids by laser welding. A plurality of subgrid modules may be connected together to form support frames. Central support frames are made of central sublattices, and end support frames are made of end sublattices. Pyramid shaped support frames can be obtained from pyramid shaped sublattice modules. The support frames can be fastened in such a way that the central support frames are located in the central part of the sieve assembly, and the end support frames are located in the end part of the sieve assembly. Connecting strips can be attached to the sieve assembly. Different areas of the screening surface can be achieved by changing the number of pyramidal subgrids included in the sieve assembly. Alternatively, the screen elements can be attached to the subgrid modules after a plurality of subgrids have been fastened together or after a plurality of support frames have been fastened together. Instead of a plurality of individual sub-grids bonded together to form a single unit, a single sub-grid structure can be made that has the desired screen assembly size. The individual sieve elements can then be attached to one sub-grid structure.

In FIG. 38 is a block diagram of the steps involved in manufacturing a sieve assembly in accordance with an exemplary embodiment of the present invention. The thermoplastic screen element may be injection molded. The subgrids can be made to receive sieve elements. The sieve elements can be attached to the subgrids, and a plurality of subgrid assemblies can be fastened together to form a screening surface. Alternatively, the subgrids may be attached to each other before the screen elements are attached.

In another exemplary embodiment, a method for screening material is provided, including attaching a sieve assembly to a vibrating screen and making the upper screening surface of the sieve assembly concave, the sieve assembly including a sieve element with a group of screening holes forming a screening surface of the sieve elements, and a subgrid , which includes a plurality of elongated structural elements forming a lattice frame having lattice holes. The sieve elements surround the grid openings and are attached to the upper surface of the subgrid. A plurality of subgrids are fastened together to form a sieve assembly, wherein the sieve assembly has a continuous screening surface of the sieve assembly consisting of a plurality of screening surfaces of the sieve elements. The sieve element is a single thermoplastic part obtained by injection molding.

In FIG. 39 is an isometric view of a vibrating screen having a single flat screen screen assembly 89 mounted thereon, with a portion of the vibrating screen cut away to show the screen assembly. The sieve assembly 89 is a single module that includes the sub-grid structure and sieve elements as disclosed herein. The sublattice structure may be one single unit or may be a plurality of sublattices bonded together. Although the screen assembly 89 is shown as a generally flat type assembly, it may be convex or concave, and may be configured to deform into a concave shape from a compression assembly or the like. It may also be designed to be tensioned from above or below, or otherwise configured to attach to various types of vibrating screens. While the illustrated embodiment of the sieve assembly covers the entire screen bed of the vibrating screen, the sieve assembly 89 can also be made in any desired shape or size and may cover only a portion of the screen bed.

In FIG. 40 is an isometric view of a sieve element 99 according to one of the exemplary

- 34 039521 embodiments of the present invention. The sieve element 99 has a substantially triangular shape. Screen element 99 is a single injection molded thermoplastic piece and has structural features (including screen hole sizes) similar to screen elements 16 and 416 as disclosed herein. Alternatively, the screen element may be rectangular, round, triangular, square, etc. Any shape can be used for the sieve element, and any shape can be used for the sub-array as long as there are grid holes in the sub-array that match the shapes of the sieve elements.

In FIG. 40A and 40B show a sieve element structure 101, which may be a sub-grid type structure, with pyramid-shaped sieve elements 99 attached thereto. In an alternative embodiment, the entire pyramidal structure of the sieve element structure 101 may be injection molded from a thermoplastic into a single sieve element having a pyramidal shape. In the configuration shown, the sieve element structure has four triangular screening surfaces of the sieve element. The bases of the two triangular screening surfaces extend from the two side elements of the sieve element, and the bases of the other two triangular screening surfaces extend from the two end elements of the sieve element. All screening surfaces rise obliquely to a central point above the end and side elements of the sieve element. The angle of inclination of the screening surfaces can be changed. The sieve element structure 101 (or, alternatively, single pyramidal sieve elements) may be attached to the subarray structure as disclosed herein.

In FIG. 40C and 40D show screen element structures 105 with attached pyramidal shaped screen elements 99 extending below the side and end elements of the screen element structure 105. Alternatively, the entire pyramid may be injection molded from thermoplastic as a single pyramid-shaped sieve element. In the configuration shown, the individual screen elements 99 form four triangular screen surfaces. The bases of the two triangular screening surfaces extend from the two side elements of the sieve element, and the bases of the other two triangular screening surfaces extend from the two end elements of the sieve element. All screening surfaces slope down to a central point below the end and side elements of the sieve element. The angle of inclination of the screening surfaces can be changed. The sieve element structure 105 (or, alternatively, single pyramidal sieve elements) may be attached to the subarray structure, as disclosed herein.

In FIG. 40E and 40F show a sieve element structure 107 comprising a plurality of pyramidal shapes extending below and rising above the side and edge elements of the sieve element structure 107. Each pyramid includes four individual sieve elements 99, but can also be configured as a single pyramidal sieve element. In the configuration shown, each screen element has sixteen triangular screen surfaces forming four separate pyramidal screen surfaces. Pyramidal screening surfaces can rise obliquely above or obliquely fall below the end elements and side elements of the sieve element. The sieve element structure 107 (or alternatively single pyramidal sieve elements) may be attached to the subarray structure as disclosed herein. Fig. 40-40F are only examples of options that can be used for screen elements and screen element support structures.

In FIG. 41-43 are cross-sectional profile views of exemplary embodiments of injection molded thermoplastic screen element surface designs that may be included in the various embodiments of the present invention discussed herein. The sieve element is not limited to the shapes and configurations described herein. Because the screen element is injection molded from a thermoplastic, many variations can easily be made and included in the various exemplary embodiments discussed herein.

In FIG. 44 shows a pre-sieve (pre-sieve) design 200 for use with vibrating screens. Pre-screen structure 200 includes a support frame 300 that is partially covered by individual pre-screen assemblies 210. Pre-screen assemblies 210 are shown with a plurality of pre-screen elements 216 mounted on pre-screen sub-grids 218. Together, different numbers of different types of subgrids can be bonded to each other to form different shapes and sizes of pre-sieve units 210. The pre-sieve units 210 are attached to the support frame 300 and form a continuous pre-screening surface 213. The pre-screen structure 200 may be installed above the primary screening surface. The pre-sieve assemblies 210, pre-sieve elements 216, and pre-sieve sub-arrays 218 may include any of the structural elements of the various screen assemblies, sieve elements, and sub-array designs disclosed herein and may be configured to be mounted on the pre-sieve support frame 300. one that can come in a variety of shapes and configurations to suit pre-screening applications. Pre-screen structure 200, pre-screen assemblies 210, pre-screen elements 216, and pre-screen subgrids 218 may be configured to be incorporated into pre-screening technologies (e.g., compatible with screen structures and configurations) disclosed in U.S. Patent Application No. 12/051658 (currently - US patent No. 8439203).

In FIG. 44A shows an enlarged view of the presieve assembly 210.

In FIG. 58 is a top isometric view of a portion of screen assembly 510. Screen assembly 510 includes screen elements 416, center subarray modules 518, and end subarray modules 514. The sieve elements 416 have been discussed in detail above with reference to FIGS. 48, 48A, 48B and 48C. The end sublattice modules 514 will be discussed in more detail below with reference to FIG. 59 and 59A, and the core sub-array modules 518 will be discussed in more detail below with reference to FIGS. 60 and 60A. The sieve assembly 510 is similar to the sieve element 410 discussed above in connection with FIG. 47. Like the sieve assembly 410, the sieve assembly includes connecting bars 12 that are attached to the ends of the sieve assembly.

In other embodiments, sieve assemblies like sieve assembly 510 of FIG. 58 (or sieve assembly 410 of FIG. 47) can be made by mixing and matching different sieve elements (e.g., 416 in FIGS. 48-48C, 516 in FIGS. 66-66C, and 616 in FIG. 70A) with different designs. sublattices (for example, 14 in Figs. 3 and 3A, 514 in Figs. 59 and 59A, 818 in Figs. 65 and 65A, 918 in Figs. 71A-71D, etc.). As discussed in more detail below, sieve element 516 has structural elements similar to sieve element 416, but sieve elements 516 and 416 are of different sizes. In one exemplary embodiment, sieve element 416 may be a 2x3 inch (-50.8x76.2 mm) sieve element, while sieve elements 516 and 616 may be 1x6 inch (-25.4x152.4 mm) sieve elements. As discussed in more detail below, sieve element 616 has smaller structural elements than sieve element 516. In addition, the narrower width of sieve elements 516 and 616 and their respective designs allows smaller elements to be made.

In FIG. 59 is a top isometric view of the end subgrid 514, and FIG. 59A is a bottom isometric view of the end subgrid 514 of FIG. 59. End sub-array 514 is an alternative embodiment of end sub-array 414 of FIG. 49 and 49A. The end subgrid 514 may be injection molded from a thermoplastic (or other suitable material) and may include all of the structural elements of the end subgrid module 414 except for the latches 42 of the end subgrid module 414. End subgrid module 514 includes latches 142, as discussed in more detail below.

With the exception of the latches 142, the end sub-arrays 514 (for example, see Figs. 59, 59A, 61 and 61A) include structural elements similar to those found in the end sub-arrays 414 (for example, see Figs. 49, 49A, 51 and 51A). For example, the end subarray 514 includes a plurality of elongated positioning elements 444, a secondary support frame 488 enclosing the lattice openings 50, a plurality of fusible rods 476, and a plurality of shortened fusible rods 478. In addition, the end subarray 514 includes parallel subarray end elements 36 and parallel side elements 38 of the sublattice, which are essentially perpendicular to the end elements 36 of the sublattice.

Screen elements 416 (eg, see FIGS. 61 and 61A) can be attached to end subgrids 514 using methods similar to those disclosed herein, including those disclosed above with respect to FIGS. 51 and 51A, methods of attaching the screen element 416 to the end sub-grids 414. For example, as shown in FIG. 61, two screen elements 416 may be positioned above the end subgrid module 514. Fusible rods 476 and 478 may be melted (eg, using laser welding, heat reflow, etc.) to fuse the two screen elements 416, with the end sub-array module 514, to form the end sub-assembly 660 shown in FIG. 61A. Additional details describing this technique for fusing the sieve element to the sublattice module are disclosed above with reference to FIG. 51 and 51A. In other embodiments, other methods may be used to combine the sieve element with the subarray. For example, the screen elements can be attached to the subgrids by at least one of mechanical means, adhesive, heat reflow, and ultrasonic welding, as discussed above.

In FIG. 60 is a top isometric view of the central sub-grid 518, and FIG. 60A is a bottom isometric view of the central sub-grid 518 of FIG. 60. Center subgrid 518 is an alternative embodiment of center subgrid 418 of FIG. 50 and 50A. The central sublattice 518 may be injection molded from a thermoplastic (or other suitable material) and may include all of the structural elements of the central sublattice module 418 except for the latches 42 of the central sublattice module 418. The central sublattice module 518 includes latches 142, as discussed in more detail below.

- 36 039521

Similarly, with the exception of the latches 142, the center sub-arrays 518 (for example, see Figs. 60, 60A, 62 and 62A) include structural elements similar to those found in the central sub-arrays 418 (for example, see Figs. 50, 50A , 52 and 52A). For example, the central subarray 518 includes a plurality of elongated positioning elements 444, a secondary support frame 488 enclosing the lattice openings 50, a plurality of fusible rods 476, and a plurality of shortened fusible rods 478. In addition, the central subarray 518 includes parallel subarray end elements 36 and parallel side elements 38 of the sublattice, which are essentially perpendicular to the end elements 36 of the sublattice.

Screen elements 416 (eg, see FIGS. 62 and 62A) can be attached to the center sub-grids 518 using methods similar to those disclosed above with respect to FIGS. 52 and 52A for methods of attaching the screen element 416 to the center subgrids 418. For example, as shown in FIG. 62, two screen elements 416 may be positioned above the central sub-array module 518. Fusible rods 476 and 478 may be melted to fuse the two screen elements 416 with the central sub-array module 518 to form the central sub-assembly 760 shown in FIG. 62A, as discussed in more detail above with reference to FIG. 52 and 52A. Additional details describing this technique for combining a sieve element with a subarray module are disclosed above with reference to FIG. 52 and 52A.

Latches 142 (for example, see Fig. 59, 59A, 60, 60A and 63C) include protruding elements similar to the elements of the latches 42. In addition to the two protruding elements of the latches 42 (for example, see Fig. 3, 3A, 49 , 49A, 50 and 50A) the latches 142 have an additional protrusion, a total of three protrusions (eg, see FIG. 63 and related discussion below). The presence of three protruding elements allows the latches 142 to create a stronger and more secure connection between the end sublattice modules 514 compared to the connection between the end sublattice modules 414 (for example, see Fig. 49 and 49A) provided by the latches 42. Similarly, the latches 142 provide more stronger and more reliable connections between the end sublattice modules 514 and the central sublattices 518, as well as between adjacent central sublattice modules 518 compared to the connections provided by the latches 42.

The use of latches 142 (eg, see FIGS. 59, 59A, 60, 60A, and 63C) is similar to the use of latches 42 (eg, see FIGS. 3, 3A and related discussion). In this regard, sub-array modules (e.g., end sub-array modules 514 and/or center sub-array modules 518) can be secured together along their respective side members 38 by inserting a latch 142 into the latch hole 40 until the three protruding latch members 142 will pass through the latch hole 40 and the side element 38 of the sublattice. As the latch 142 is inserted into the latch hole 40, the protruding elements of the latch 142 will slide together until a portion of each protruding element extends beyond the side sublattice element 38, ensuring that the snap portions of the latch 142 engage with the interior of the side sublattice element 38 .

As discussed above with reference to FIG. 3 and 3A, when the latch portions of latch 142 engage in latch hole 40, the side sublattices of the two separate end sublattices 514 will be side by side and secured together (eg, see FIGS. 3, 3A, and related discussion). Likewise, when the latch portions of latch 142 enter latch hole 40, the side sub-grid members of the two separate center sub-grids 518 will be positioned side by side and secured together. End member 36 of end sub-grid 514 can similarly be attached to end member 36 of central sub-grid 518. Similarly, end members 36 of two adjacent center sub-grids 518 can be fastened together. The subgrids can be separated by applying force to the protruding members of the latch 142 so that the protruding members move together, allowing the latch portions to exit the latch hole 40.

In other embodiments, the latches 142 may be configured to create a permanent connection between the sub-arrays, which, once connected, cannot be separated without breaking the latches 142 or one or more of the sub-arrays. Such embodiments, having latches 142 that can create permanent connections, can be useful for creating screen assemblies that can be secured in a vibrating screen based on compression forces, as disclosed, for example, in US patents No. 7578394 and 9027760, each of which contains incorporated herein by reference. In this way, it is possible to create sieve assemblies that can withstand compressive forces in the range of 2000-3000 pounds (~907-1361 kg) applied to the edges of the sieve assemblies. In addition, such sieve assemblies can be configured to operate in a vibrating screen with vibration acceleration in the range of 3-9 G.

In FIG. 63 is a top isometric view of a pyramidal end sub-array 558, and FIG. 63A is a bottom isometric view of the pyramidal end sub-array 558 shown in FIG. 63. Alternative pyramidal subarray 558 in FIG. 63 and 63A is an alternative embodiment of the pyramidal end sub-array 458 shown in FIG. 53 and 53A. The pyramidal subarray 558 may be injection molded from a thermoplastic (or other suitable material) and may comprise all of the pyramidal end subarray 458 structural elements except for the pyramid end subarray module 458 latches 42. End sublattice 558 pyramidal shape contains latches

242.

Similarly, with the exception of the latches 242, the pyramidal subarray 558 (eg, see FIGS. 63 and 63A) contains structural elements similar to those of the pyramidal end sublattice 458 (eg, see FIGS. 53 and 53A). For example, the pyramid-shaped end sub-array 558 includes a ridge portion 66, sub-array side members/base members 64, and sloped surfaces 70 that peak at the ridge portion 66 and extend downward to the side member 64. The pyramid-shaped sub-arbor 558 also has triangular end members. 62. The pyramidal end subarray 558 may have a plurality of elongated positioning elements 444 and second adhesive means such as a plurality of fusible rods 476 and short fusible rods 478. The pyramidal end subarray 558 may include a secondary support frame 488 enclosing the lattice openings, and may include a flattened portion 465 of the crest, and may also have clamps 490 on the crest 66 for welding jig.

The latches 242 are similar to the latches 142 in that they have an additional structure that provides a stronger and more secure connection between adjacent pyramid-shaped end sublattices 458. For example, the latches 242 have two identical protrusions that are structurally similar to the two protrusions of the latches 42 and 142. The latches 242 also have an additional central protrusion (for example, see FIG. 63D below) that also fits into the interior of the side sublattice element 64 .

Latches 142 and 242 provide an additional structure to create strong connections between the subgrid modules and can withstand compression forces in the range of 2000 to 3000 pounds (~907-1361 kg) on the screen assembly. In addition, when screen assemblies are formed from screen subassemblies, the resulting assemblies using latches 142 and 242 provide strong connecting forces between the subassemblies so that the resulting screen assembly can withstand high vibrational accelerations of the order of 3G to 9G. The disclosed screen assemblies are also designed to handle abrasive materials (eg, fluids having a few percent to 65 percent solids) and high load requirements (eg, fluids having specific gravity up to 18 pounds per gallon (~ 2157 kg/m ³ )), as described in more detail below.

In FIG. 63B, 63C, and 63D compare the structural elements of latches 42 (eg, see FIGS. 3 and 3A), 142 (eg, see FIGS. 59-62A), and 242 (eg, see FIGS. 63 and 63A), respectively. In FIG. 63B is an isometric view of latch 42. As shown in FIG. 63B, the latch 42 has a first protrusion 42a and a second protrusion 42b that engage with the latch opening 40 (eg, see FIG. 59). In FIG. 63C is an isometric view of a latch 142 which has a first lobe 142a and a second lobe 142b that are similar to the respective first lobe 42a and second lobe 42b of the latch 42 of FIG. 63B (see also FIGS. 3 and 3A).

However, the latch 142 is provided with a third projecting member 142c as shown in FIG. 63C. The three protrusions 142a, 142b and 142c of latch 142 provide a stronger and more secure connection between the subgrids as discussed above.

In FIG. 63D is an isometric view of latch 242. As shown in FIG. 63D, the latch 142 has a first projection 242a and a second projection 242b that are similar to the first projection 42a and the second projection 42b of the latch 42 (for example, see FIGS. 3, 3A, 63B) and are also similar to the first projection 142a and the second protruding element 142b of the latch 142 (for example, see Fig. 63C). However, as noted above, the latch 142 of FIG. 63D also has a central protrusion 242c that engages the top and bottom edges of the latch hole 40 (eg, see FIG. 63). The latch 242 provides additional stability to the connections between the sublattices in that the central protruding member 242c prevents the two sublattices secured by the latch 242 from pivoting about the axis 242d as shown in FIG. 63d.

The above discussion can be directly generalized in that any design having latches 42 can be generalized to a similar design having latches 142 or 242 (eg, see FIGS. 63C and 63D). For example, the pyramid-shaped central sublattice 460 shown in FIG. 54 and 54A can similarly be generalized to a pyramid-shaped central sub-lattice design having latches 142 or 242 (not shown). Likewise, methods for attaching screen members 416 to such pyramid-shaped sub-arrays, as discussed above in connection with FIGS. 55, 55A, 56, and 56A can be used to attach the screen members 416 to the pyramidal-shaped generalized central subgrids, since the latches 42, 142, and 242 play no role in the process of attaching the screen members 416.

- 38 039521

In FIG. 64 is a top isometric view of the end subgrid 718, and FIG. 64A is a bottom isometric view of the end subgrid 718 shown in FIG. 64. End sub-array 718 is an alternative embodiment of end sub-array 514 shown in FIG. 59 and 59A. The end subgrid 718 may be injection molded from a thermoplastic (or other suitable material) and may contain structural elements similar to those of the end subgrid module 514. For example, the end subarray 718 includes a plurality of elongated positioning elements 444, a secondary support frame 488 covering the lattice openings 50, a plurality of fusible rods 476, and a plurality of short fusible rods 478. In addition, the end subarray 718 includes parallel end subarray elements 136 and parallel side elements 138 of the sublattice, which are essentially perpendicular to the end elements 136 of the sublattice. The sub-array 718 may also have latches 242 similar to those of the pyramid-shaped end sub-array 558 (eg, see FIGS. 63 and 63A). Alternatively, in one embodiment, the end sub-array 718 may use other latches, such as the latches 142 of the end sub-array 514 (for example, see Figs. 59 and 59A) or the latches 42 of the end sub-array 14 (for example, see Figs. 3 and 3A) .

However, unlike the end sub-grid 514, the end sub-grid 718, at approximately the same length as the end sub-grid 514, has a width that is approximately half the width of the end sub-grid 514. In other words, the length measured along the parallel side sub-grid elements 138 for the end sub-grid 718 is substantially equal to the length measured along the parallel subarray side members 38 for the end subarray 514, but the distance measured along the parallel subarray end member 136 for the subarray 718 is substantially equal to half the distance measured along the subarray end member 36 of the end subarray 514 The shorter width of the end subarray 718 has the advantage that it can support corresponding screen elements 516 (eg, see FIGS. 66, 66A, 66B, and 66C) having half the width of the sieve elements 416 (eg, see FIG. 48). , 48A, 48B and 48C). Screen elements 516 having a shorter width allow screen elements 516 to be fabricated having smaller features such as smaller screen openings 86 and smaller surface features 84 (eg, see FIG. 2D), as discussed in more detail below.

In FIG. 65 is a top isometric view of the central sub-grid 818, and FIG. 65A is a bottom isometric view of the central sub-grid 818 shown in FIG. 65. Center sub-array 818 is an alternative embodiment of the center sub-array 518 shown in FIG. 60, and 60A. The central sublattice 818 may be injection molded from a thermoplastic (or other suitable material) and may include structural elements similar to those of the central sublattice module 518. For example, the central subarray 818 includes a plurality of elongated positioning elements 444, a secondary support frame 488 covering the lattice openings 50, a plurality of fusible rods 476, and a plurality of shortened fusible rods 478. In addition, the central subarray 818 includes parallel end elements 136 of the subarray and parallel side elements 138 of the sublattice, which are essentially perpendicular to the end elements 136 of the sublattice. The central sublattice 818 may also have latches 242 similar to those of the pyramidal central sublattice 558 (eg, see FIGS. 63 and 63A). Alternatively, other latches may be used in one embodiment of the central sub-array 818, such as the latches 142 of the central sub-array 518 (for example, see FIGS. 60 and 60A) or the latches 42 of the central sub-array 18 (for example, see FIGS. 4 and 4A) .

However, unlike the center sub-grid 518, the center sub-grid 818, while approximately the same length as the center sub-grid 518, has a width that is approximately half the width of the center sub-grid 518 (for example, compare Figs. 65 and 65A with Figs. 60 and 60A) . In other words, the length measured along the parallel side subgrid members 138 for the center subgrid 818 is substantially the same as the length measured along the parallel side subgrid member 38 for the center subgrid 518, but the distance measured along the parallel subgrid end members 136 for the subgrid 818 is , essentially half the distance measured along the parallel end members 36 of the subarray of the central subarray 518. The shorter width of the central subarray 818 has the advantage that it can support the corresponding screen elements 516 (for example, see Fig. 66, 66A, 66B and 66C) having half the width of the sieve elements 416 (eg, see FIGS. 48, 48A, 48B, and 48C). Screen elements 516 having a shorter width allow screen elements 516 to be fabricated having smaller structural features, such as smaller screen openings 86 and smaller surface features 84 (eg, see FIG. 2D), as discussed in more detail below.

As discussed in more detail below (for example, with reference to Figs. 70-74D), screen elements (for example, see Fig. 70A) having smaller structural elements, such as smaller screen holes 86, and smaller surface features 84 ( for example, see Figures 2D and Tables 1-4 below) are capable of being supported by corresponding sub-array structures having additional structural elements (for example, see Figures 71-71D, 72 and 72A) that support corresponding reinforcing elements (eg, see FIGS. 71E, 71F, 72B, 72C, 74B, and 74C) of the screening elements. Smaller screening structural elements of sieve elements, which are supported by an additional structure of subgrids, can be mounted in screening units having an increased screening area.

In this way, screen elements are provided that are optimally sized (large enough to effectively mount the entire screen assembly structure, but small enough to be injection molded (micromolded in some embodiments) of extremely small screen hole-forming structures without solidification (i.e., e. solidification of the material in the form until it is completely filled));

have an optimal screening area (designs that form holes and support the holes are of a minimum size to increase the total screening area used for screening while maintaining, in some embodiments, very small screening holes necessary for proper separation of materials to a given standard);

have durability and strength, can work in different temperature ranges; chemically resistant;

structurally stable;

highly versatile for sieve assembly manufacturing processes and designed to provide customized configurations for specific applications.

In addition, the screen elements, sub-grids and screen assemblies can be of different shapes and sizes, provided that structural support elements of the sub-grids are provided to support the respective reinforcing elements of the screen elements. The screens, subgrids and screen assemblies are designed to withstand high vibration forces (e.g., accelerations in the 3-9 G range), abrasive materials (e.g., fluids having a few percent to 65 percent solids), and high load requirements (e.g. , fluids having specific gravity up to 18 pounds per gallon (~2157 kg/m ³ )). The screen assemblies are also capable of withstanding a compressive load of up to 2000-3000 pounds (~907-1361 kg) on the edges of the screen assemblies, as disclosed, for example, in US Pat. . In addition, the disclosed screen assemblies are designed such that the size of the screening holes is maintained under operating conditions, including the aforementioned compressive load, high vibration forces, and in the presence of heavy fluids.

In FIG. 66, 66A, 66B, and 66C show screen element 516, which is similar to screen element 416 (eg, see FIGS. 48, 48A, 48B, and 48C). For example, screen element 516 may include positioning holes 424 that may be located at four corners of screen element 516 and at various locations along end element 120 and side element 122 of screen element 516 (for example, see FIGS. 66 and 66A). More or fewer positioning holes 424 can be provided on the screen element 516, and a variety of configurations can also be provided. The positioning holes 424 may be used to position the sieve element 516 on the subgrid (eg, as on the end subgrid 718 of FIGS. 64 and 64A or on the central subgrid 818 of FIGS. 65 and 65A). The sieve element 516 may further include a central positioning hole 524. Alternatively, in one embodiment, the sieve element 516 may be positioned without positioning holes 424. The sieve element 516 may include a plurality of tapered counter channels 470, which may facilitate the removal of the sieve element 516 from a mold, wherein the mold may have ejector pins configured to eject the sieve element from the mold (eg, see FIGS. 66 and 66A).

In this example, sieve elements 516 (eg, see FIGS. 66-66C) are twice the length of sieve elements 416 but half the width of sieve elements 416 (eg, see FIGS. 48-48C). For example, the distance measured along portion 122 of sieve element 516 is essentially twice the distance measured along portion 22 of sieve element 416 (eg, see FIG. 48). However, the distance measured along end portion 120 of sieve element 516 is essentially half the distance measured along end portion 20 of sieve element 416 (eg, see FIG. 48). Selecting shorter width screen elements 516 allows screen elements 516 to be made with smaller features such as smaller screen openings 86 and smaller surface features 84 (eg, see FIG. 2D), as discussed in more detail below.

Similar to screen element 416 (eg, see FIGS. 48B and 48C), screen element 516 may have structural elements on its underside as shown in FIG. 66B and 66C. For example, screen element 516 may have a plurality of hollow pockets 472 that may be located along end portions 120 and side portions 122 between positioning holes 424. As with screen element 416, hollow pockets 472 (for example, see FIG. 66C) may serve as an adhesive for the sieve element 516, which can be configured to mate with an optional second adhesive on the top surface of the subgrid module (e.g., as

- 40 039521 on the end subgrid 718 of FIG. 64 and 64A or on the central subgrid 818 of FIG. 65 and 65A).

As shown, for example, in FIG. 67 and 67A, sieve elements 516 may be attached to end subarray 718 to create end sieve subassembly 860 using methods similar to those disclosed above for attaching sieve elements 416 to end subarray 514 to create end subassembly 660 (for example, see FIG. .61 and 61A). For example, the positioning holes 424 and 524 of the sieve element 516 (for example, see Fig. 66A) can be engaged with the positioning elements 444 of the end subgrid 718. as discussed in more detail above with reference to FIG. 51, 51A, 61 and 61A.

In contrast to the situation shown in FIG. 61, when the end sub-grid 514 is surrounded by two sieve elements 416, as shown in FIG. 67, end sub-array 718 is covered by a single sieve element 516. This situation arises because sieve element 516 is twice as long and half as wide as sieve element 416, while end sub-array 718 is the same length but half as wide across. compared with the end subgrid 514. The shorter width and longer length of the screen element 516 provides smaller structural features such as screen holes 86 and smaller surface features 84 (for example, see Fig. 2D) to be manufactured (for example, by casting pressurized thermoplastic) as discussed in more detail below.

As shown, for example, in FIG. 68 and 68A, sieve elements 516 may be attached to the center sub-array 818 to create the center sieve sub-assembly 960 using methods similar to those disclosed above for attaching the sieve elements 416 to the central sub-array 518 to create the central sub-assembly 760 (for example, see FIG. 62 and 62A). For example, fusible rods 476 and 478 can be melted to fuse screen element 516 to central subgrid 818, as discussed in more detail above with reference to FIG. 52, 52A, 62 and 62A.

In contrast to the situation shown in FIG. 62, when two screen elements 416 surround the central sub-grid 518, as shown in FIG. 68, a single sieve element 516 encloses the center sub-array 818. This situation occurs because the sieve element 516 is twice the length and half the width of the sieve element 416, while the central sub-array 818 is the same length but half the width. compared to the central subgrid 518. The shorter width and longer length of the screen element 516 allows for smaller structural features such as screen holes 86 and smaller surface features 84 (eg, see FIG. 2D) to be fabricated, as discussed in more detail. below.

As shown, for example, in FIG. 69 and 69A, the screen assembly 80 can be formed by combining end screen subassemblies 860, center screen subassemblies 960, and screen subassemblies having pyramid-shaped sub-arrays, such as pyramid-shaped end sub-assemblies based on pyramidal end sub-arrays 58 and pyramid-shaped center subassemblies based on pyramidal the central sublattices 60 disclosed above. The pyramid-shaped subassemblies may include sieve elements 16 (eg, see FIGS. 2-2C), 416 (eg, see FIGS. 48-48C), or 516 (eg, see FIGS. 66-66C). By using end screen sub-assemblies 860 and center screen sub-assemblies 960, each having half the width of the end sub-arrays 514 and center sub-arrays 518, respectively, the pyramid-shaped sub-assemblies can be positioned closer together than similar assemblies shown in other embodiments, such as the sieve units shown, for example, in FIG. 21 and 21a.

In FIG. 70 and 70A compare sieve element 516 (see FIG. 70) with an alternative embodiment of sieve element 616 (see FIG. 70A) having smaller structural elements than those of sieve element 516. The sieve element 616 is configured to support more small structural elements, including smaller screening holes 86 and smaller surface features 84 (for example, see Fig. 2D), as discussed in more detail below.

The sieve element 616 may be injection molded from a thermoplastic (or other suitable material) and may have structural elements similar to those of the sieve element 516. For example, the sieve element 616 may include positioning holes 424, which may be located at four corners. screen element 616 and at various locations along the end element 120 and side element 122 of the sieve element 616. More or fewer positioning holes 424 on the sieve element 616 may be provided, and many configurations may also be provided. Positioning holes 424 may be used to position the sieve element 616 on the subgrid (eg, as on the end subgrid 718 of FIGS. 67 and 67A or on the central subgrid 818 of FIGS. 68 and 68A). The sieve element 616 may further include a central positioning hole 524. Alternatively, in one embodiment, the sieve element 616 may be positioned without positioning holes 424. The sieve element 616 may include a plurality of tapered counter channels 470, which may facilitate the removal of the sieve element 616 from cast

- 41 039521 molds, and the mold may have ejector pins configured to push the sieve element out of the mold.

Screen element 616 may have a plurality of hollow pockets 472 that may be located along end portions 120 and side portions 122 between positioning holes 424. configured to interface with a complementary second adhesive means on the upper surface of the sublattice module. Thus, the sieve element 616 can be attached to the sub-array using methods similar to those disclosed above for attaching the sieve element 516 to the sub-array. an element 516 with a sub-array (for example, an end sub-array 718 in Fig. 67 or a central sub-array 818 in Fig. 68).

The differences between sieve element 516 (of FIG. 70) and sieve element 616 (of FIG. 70A) relate to support structures as follows. Screen element 516 has a first group of reinforcing elements 32, and sieve element 616 has a first group of reinforcing elements 132. The linear density of the reinforcing elements 132 of the sieve element 616 is higher than the linear density of the reinforcing elements 32 of the sieve element 516. In this example, the sieve element 516 has a a total of ten reinforcing members 32 spanning a direction parallel to end member 120, while screen member 616 has a total of fourteen reinforcing members 132 spanning a direction parallel to end member 120. The greater linear density of the reinforcing members 132 of sieve member 616 provides greater structural strength of screen element 616 compared to screen element 516. In addition, as discussed in more detail below, more reinforcing elements 132 provide more screen surface elements 84 and screen holes 86, each of which is are located between reinforcing elements 132.

The sieve element 516 has a second group of reinforcing elements 34. The sieve element 616 also includes a second group of support elements 34 along with an additional third group 134 of reinforcing 134 elements. In FIG. 70 shows two of the second group of support elements 34 of the sieve element 516. In FIG. 71 also shows corresponding two of the second group of support elements 34 of the sieve element 616. Additional third groups of reinforcing elements 134 of the sieve element 616 are shown located between adjacent reinforcing elements 34 of the second group of reinforcing elements 34. Collectively, the second group of reinforcing elements 34, combined with the third group of reinforcing elements elements 134 of the sieve element 616, provides a higher linear density of the reinforcing elements in contrast to the linear density of the second reinforcing elements 34 of the sieve element 516. greater structural strength of the 616 sieve element compared to the 516 sieve element.

In FIG. 71 and 71A compare the central sublattice module 818 (FIG. 71) with an alternative embodiment of the central sublattice module 918 (FIG. 71A) having additional structural support members. Additional structural support elements of the central subgrid 918 accordingly provide additional support for the third group of reinforcing elements 134 of the sieve element 616, as discussed in more detail below.

The central sublattice 918 may be injection molded from a thermoplastic (or other suitable material) and may include structural elements similar to those found in the central sublattice module 818. For example, the central subarray 918 includes a plurality of elongated positioning elements 444, a plurality of fusible rods 476, and a plurality of shortened fusible rods 478. In addition, the central subarray 918 includes parallel end subarray elements 136 and parallel side subarray elements 138, which are essentially , are perpendicular to the end elements 136 of the sublattice. The central sublattice 918 may also have latches 242 similar to those of the central sublattice 818 (eg, see FIG. 65) and the pyramid-shaped central sublattice latches 558 (eg, see FIGS. 63 and 63A).

Similar to the central sub-grid 818, the central sub-grid 918 has a secondary support frame 488 enclosing the lattice openings 50 (eg, see lattice openings 50 in FIG. 65A). In contrast to the central sublattice 818, the central sublattice 918 has an additional tertiary support frame 588, as shown in more detail in FIG. 71B, 71C, 71D and 71F.

In FIG. 71B is an enlarged view of region A in FIG. 71A.

The view in Fig. 71B shows two secondary support framing members 488 that are parallel to the end members 136 and two secondary framing members 488 that are parallel to the side members 138. The additional tertiary support frame 588 includes members that are parallel to the end members 136 and distributed between adjacent secondary framing members. 488 that are parallel to the end members 136. The combination of the secondary frame 488 and the tertiary frame 588 together provide a frame that has increased linear density of the support members along a direction parallel to the side members 138. The additional support members of the tertiary frame 588 respectively provide support for the third group of reinforcing elements 134 of the sieve element 616 (for example, see Fig. 70A), as described in more detail below. Likewise, the secondary support frame supports 488, which are parallel to the end elements 136, support the respective second group of support elements 34 of the screen element 616.

In FIG. 71C is a plan view of the central sub-grid 918, and FIG. 71D shows a side view of the central sublattice 918. The central sublattice 918, like the central sublattice 818, includes a secondary support frame 488. However, unlike the central sublattice 818, the central sublattice 918 includes a tertiary support frame 588, as discussed above. And in Fig. 71C, and in FIG. 71D shows elements of tertiary support frame 588 distributed between adjacent elements of secondary support frame 488 that are parallel to end members 136. As noted above, the combination of secondary frame 488 and tertiary frame 588 together provides a frame that has increased linear density of support members along a direction parallel to side elements 138.

In FIG. 71E and 71F show the correspondence between the reinforcing elements of the screen elements 516 and 616 and the corresponding elements of the support frames 488 and 588, respectively. For clarity of comparison, in FIG. 71E, sieve 516 is positioned adjacent to central sub-grid 818, and in FIG. 71F, the sieve 616 is located adjacent to the central sub-grid 918. In FIG. 71E, the two reinforcing elements 34 of the sieve element 516 are shown in alignment with the corresponding elements of the secondary support mesh 488 of the central subgrid 818. Similarly, in FIG. 71F, the two reinforcing elements 34 of the sieve element 616 are shown aligned with the corresponding elements of the secondary support mesh 488 of the central subgrid 918. In addition, in FIG. 71F shows two elements from the third group of support elements 134 that are spatially aligned with the corresponding elements of the tertiary support grid 588 of the central sublattice 918. As noted above, the additional tertiary support frame 588 includes elements that are parallel to the end elements 136 and distributed between adjacent elements of the secondary frame 488 that are parallel to the end members 136. Thus, the combination of the secondary frame 488 and the tertiary frame 588 together provide a frame that has increased linear density of the support members along a direction parallel to the side members 138.

The foregoing discussion regarding end sub-arrays 818 and 918 can be generalized to other sub-array designs, including end sub-arrays as well as pyramidal center and end sub-arrays. For example, in FIG. 72 shows a pyramid-shaped end sublattice 558 having a lattice frame with a first linear density of support elements along a direction parallel to side element 64. The support elements in FIG. 72 and 72A are parallel to end member 62. In FIG. 72A shows an alternate embodiment of the pyramidal end sub-array 658 that includes a lattice framework having a higher linear density of support elements along a direction parallel to the side member 64, as opposed to the pyramid-shaped end sub-arbor 558 of FIG. 72. Additional support elements of the end subgrid 658 provide support for the reinforcing elements of the sieve element 516 as follows.

In FIG. 72B shows the supporting members 688 of the support frame of the end sub-array 558, which are spatially aligned with the respective reinforcing members 34 of the sieve element 516. 818 are aligned with the reinforcing elements 34 of the sieve element 516 in FIG. 71E.

Likewise, the pyramidal end sublattice 658 shown in FIG. 71F has support elements 688 that are spatially aligned with the respective reinforcing elements 34 of the sieve element 616. However, unlike the pyramidal end subarray 558, the pyramid end subarray 658 includes additional support elements 788. As shown in FIG. 72C, the support elements 788 of the pyramid-shaped end sub-array 658 are spatially aligned with the reinforcing elements 134 of the sieve element 616. In this regard, the pyramid-shaped end sub-arbor 658 provides additional structural support to the sieve element 516 compared to what the end sub-array 558 provides to the sieve element 416.

The following discussion provides additional details of screen element 616 with reference to FIG. 73-73D and 74-74D. As noted above, sieve element 616 is similar to sieve element 516 in that it is twice as long and half narrower than sieve element 416 (for example, compare the relative dimensions of sieve elements 416 in Fig. 61 with sieve element 516 in Fig. 67). The smaller width allows 616 screens to be made with smaller features such as

- 43 039521 smaller screening holes 86 and smaller surface features 84 (for example, see Fig.

2D).

In FIG. 73 is a plan view of the sieve element 616 previously shown, for example, in FIG. 70A, 71F and 72C. In FIG. 73, the direction A-A of the first cross section and the direction CC of the second cross section are determined. In FIG. 73A shows a first cross section of the sieve element 616 of FIG. 73 defined by the first cross-sectional direction A-A of FIG. 73 View of FIG. 73A is shown on a 2:1 scale. In cross section A-A in Fig. 73A shows a plurality of reinforcing elements 132 (eg, see discussion relating to FIG. 70A) that are parallel to side edges 122 of screen element 616. FIG. 73B is an enlarged view of fragment B of the first cross section shown in FIG. 73A. In FIG. 73B also shows reinforcing elements 132.

In FIG. 73C shows a second cross section of the sieve element 616 of FIG. 73 defined by the second C-C cross-sectional direction of FIG. 73 View of FIG. 73C is shown on a 2:1 scale and illustrates reinforcing members 34 and 134 (eg, see discussion relating to FIGS. 70A, 71F, and 72C) that are parallel to end portions 120 of screen element 616. FIG. 73D is an enlarged second cross-sectional view of the sieve element 616 shown in FIG. 73C. In FIG. 73D, in addition to the reinforcing elements 34 and 134 shown in FIG. 73C, a plurality of screen holes 86 and surface features 84 are shown. Screen openings 86 and surface features 84 are discussed in more detail below with reference to FIGS. 74C and 74D.

In FIG. 74 shows a plan view of a central sieve subassembly obtained by attaching a sieve element 616 to an end subarray module 818, similar to the sieve assembly 960 shown in Figure 68A. In FIG. 74 defines the cross-sectional direction A-A, which is used to define the views in FIG. 74B, 74C and 74D. In FIG. 74A is a side view of the central screen subassembly 960 of FIG. 74 showing screen element 616 and end subgrid module 818. For illustrative purposes, the sieve element 616 is located slightly above the end subgrid module 818.

In FIG. 74B is a cross-sectional view of the central sieve subassembly of FIG. 74 defined by the cross-sectional direction A-A in FIG. 74. In FIG. 74B also shows detail area B, which is enlarged in FIG. 74C and 74D. Support frame elements 488 and 558 are also shown. As discussed above, support frame elements 488 and 588 are spatially aligned and provide support for reinforcing elements 34 and 134 of sieve element 516, respectively.

In FIG. 74C is an enlarged view of a cross-sectional detail B of the central sieve subassembly of FIG. 74B. Fig. 74C shows details similar to those shown in FIG. 10C. In this regard, in FIG. 74C shows the subarray end member 36, the secondary subarray support member 488, and the tertiary subarray support frame 588 (eg, see FIGS. 71, 71A, 71B, 71C, 71D, and 71F). In FIG. 74C also shows the reinforcing elements 34 and 134 shown above in FIG. 73D. The detail area labeled C in FIG. 74C, in FIG. 74D is shown enlarged.

In FIG. 74D shows a cross-sectional view of a plurality of surface features 84 separated by a set of screen holes 86. As discussed above with reference to FIG. 2D, the surface features 84 have a thickness T which may vary depending on the screening application and the configuration of the screening holes 86. T can be selected depending on the desired screening area and the width W of the screening holes 86. The screening holes 86 are elongated slots having a length L and width W (for example, see Fig. 2D), which may vary for the selected configuration. Slits having a length L (eg, see FIG. 2D for the definition of L not shown in FIG. 74D) extend substantially in the plane of FIG. 74D and shown horizontally in FIG. 2D.

In table. 1 (below) shows the percent open area of exemplary embodiments of screen assemblies including screen element 616 as a function of the parameters W, T, and L describing the width of the screen openings 86, the width of the surface elements 84, and the length of the screen openings 86, respectively. As disclosed above, the open area percentage shown below is achieved by creating exemplary screen assemblies that include elements 616 and exemplary subarray structures (e.g., subarrays 818 and 918) having appropriate structural elements to support screen elements 616. Thus, suitably designed screen elements 616 and sub-grid designs (eg, sub-grids 818 and 918) work together to maximize the screening area.

In this example, the surface features 84 have a fixed thickness T=0.014 inches (~0.3556 mm). The screen openings 86 have a fixed length L=0.076 inches (~1.9304 mm) and a variable width W. As can be expected for a fixed number of screen openings 86, the percentage of open area decreases with the width W of each screen opening 86. In this example, the percentage open section varies from a minimum free section of 6.2% for the smallest width W=0.0017 inch (~0.0431 mm) to a maximum free section of 23.3% for the largest width W=0.0071 (~0. 1803 mm).

- 44 039521

Table 1

mesh W (inch/mm) T (inch/mm) L (inch/mm) % open area 80 0.0071/0.1803 0.014/0.3556 0.076/1.9304 23.3 100 0.0059/0.1499 0.014/0.3556 0.076/1.9304 20.3 120 0.0049/0.1245 0.014/0.3556 0.076/1.9304 17.6 140 0.0041/0.1041 0.014/0.3556 0.076/1.9304 13.4 170 0.0035/0.0889 0.014/0.3556 0.076/1.9304 12.2 200 0.0029/0.0737 0.014/0.3556 0.076/1.9304 10.3 230 0.0025/0.0635 0.014/0.3556 0.076/1.9304 9.1 270 0.0021/0.0533 0.014/0.3556 0.076/1.9304 7.9 325 0.0017/0.0431 0.014/0.3556 0.076/1.9304 6.2

In table. 2 (below) shows the percentage of open area of other exemplary embodiments of sieve assemblies, including the sieve element 616, as a function of the parameters W, T, and L. include elements 616 and exemplary subarray structures (e.g., subarrays 818 and 918) having appropriate structural elements to support screen elements 616.

In table. 2 shows the effect of reducing the length L of the screen holes 86 and reducing the width T of the surface elements 84 so that the screen element 616 can include more screen elements. In this example, surface features 84 have a fixed thickness T=0.007 inches (-0.1778 mm). The screen openings 86 have a fixed length L=0.046" (-1.1684 mm) and a variable width W. The percentage of open area obtained varies from a minimum open section of 10.1% for the smallest width W=0.0017" (-0. 0431 mm) to a maximum free section of 27.3% for the widest width W=0.0071" (-0.1803 mm). Thus, the maximum open area percentage is increased from 23.3 to 27.3% by decreasing T from 0.014" (-0.3556 mm) to 0.007" (-0.1778 mm) and decreasing L from 0.076" (-1 .9304 mm) to 0.046 inches (-1.1684 mm), as can be seen from a comparison of the results from table. 2 with the results from the table. 1. As noted above, the increase in maximum open area percentage occurs because as the size of the screen openings 86 and surface features are reduced, more screen openings can be included in the screen element 516.

table 2

mesh W (inch/mm) T (inch/mm) L (inch/mm) % open area 80 0.0071/0.1803 0.007/0.1778 0.046/1.1684 27.3 100 0.0059/0.1499 0.007/0.1778 0.046/1.1684 25.2 120 0.0049/0.1245 0.007/0.1778 0.046/1.1684 23.1 140 0.0041/0.1041 0.007/0.1778 0.046/1.1684 20.5 170 0.0035/0.0889 0.007/0.1778 0.046/1.1684 18.5 200 0.0029/0.0737 0.007/0.1778 0.046/1.1684 16.5 230 0.0025/0.0635 0.007/0.1778 0.046/1.1684 14.9 270 0.0021/0.0533 0.007/0.1778 0.046/1.1684 12.8 325 0.0017/0.0431 0.007/0.1778 0.046/1.1684 10.1

In table. 3 (below) shows the percentage of open area of additional exemplary embodiments of sieve assemblies, including the sieve element 616, as a function of the parameters W, T, and L. include elements 616 and exemplary subarray structures (e.g., subarrays 818 and 918) having appropriate structural elements to support screen elements 616.

In table. 3 shows that this trend may continue.

In this example, surface features 84 have a fixed thickness T=0.005 inches (-0.127 mm). The screen openings 86 have a fixed length L=0.032" (-0.8128 mm) and a variable width W. The resulting percentage of open area varies from a minimum open section of 12.1% for the smallest width W=0.0017" (-0. 0431 mm) to a maximum free section of 31.4% for the widest width W=0.0071" (-0.1803 mm). Thus, by decreasing T from 0.007" (-0.1778 mm) to 0.005" (-0.127 mm) and decreasing L from 0.046" (-1.1684 mm) to 0.032" (-0.8128 mm), the maximum percentage living section increases from 27.3 to 31.4%, as can be seen from a comparison of the results from table. 3 with the results from the table. 2.

-45039521

Table 3

mesh W (inch/mm) T (inch/mm) L (inch/mm) % open area 80 0.0071/0.1803 0.005/0.127 0.032/0.8128 31.4 100 0.0059/0.1499 0.005/0.127 0.032/0.8128 29.3 120 0.0049/0.1245 0.005/0.127 0.032/0.8128 27.0 140 0.0041/0.1041 0.005/0.127 0.032/0.8128 24.1 170 0.0035/0.0889 0.005/0.127 0.032/0.8128 22.0 200 0.0029/0.0737 0.005/0.127 0.032/0.8128 19.7 230 0.0025/0.0635 0.005/0.127 0.032/0.8128 16.4 270 0.0021/0.0533 0.005/0.127 0.032/0.8128 14.7 325 0.0017/0.0431 0.005/0.127 0.032/0.8128 12.1

In table. 4 (below) shows the percentage of open area of additional exemplary embodiments of sieve assemblies, including the sieve element 616, as a function of the parameters W, T and L. As disclosed above, the percentage of open area shown below is provided by creating exemplary sieve assemblies include elements 616 and exemplary subarray structures (e.g., subarrays 818 and 918) having appropriate structural elements to support screen elements 616.

In table. 4 shows a further increase in the percentage of open area with decreasing T and L. In this example, the surface features 84 have a fixed thickness T=0.003 inches (~0.0762 mm). The screen openings 86 have a fixed length L=0.028 inches (~0.7112 mm) and a variable width W. 0432 mm) up to a maximum free section of 32.2% for the widest width W=0.0071" (~0.1803 mm). Thus, by reducing T from 0.005 (~0.127 mm) inches to 0.003 inches (~0.0762 mm) and reducing L from 0.032 inches (~0.8128 mm) to 0.028 inches (~0.7112 mm), the maximum percentage of live section increases from 31.4 to 32.2%, as can be seen from a comparison of the results from table. 4 with the results from the table. 3.

Table 4

mesh W (inch/mm) T (inch/mm) L (inch/mm) % open area 80 0.0071/0.1803 0.003/0.0762 0.028/0.7112 32.2 100 0.0059/0.1499 0.003/0.0762 0.028/0.7112 30.1 120 0.0049/0.1245 0.003/0.0762 0.028/0.7112 27.8 140 0.0041/0.1041 0.003/0.0762 0.028/0.7112 25.2 170 0.0035/0.0889 0.003/0.0762 0.028/0.7112 23.1 200 0.0029/0.0737 0.003/0.0762 0.028/0.7112 20.1 230 0.0025/0.0635 0.003/0.0762 0.028/0.7112 17.2 270 0.0021/0.0533 0.003/0.0762 0.028/0.7112 15.3 325 0.0017/0.0431 0.003/0.0762 0.028/0.7112 13.2

According to embodiments, a plurality of sub-assemblies may be fastened together to form sieve assemblies having a desired total screening area. For example, a plurality of subgrids are bonded together to form a screen assembly having a screening surface that has a total screening area in the range of approximately 0.4 to 6.0 m ² . In various embodiments, sieve assemblies can be made having a total screening area of 0.41; 0.68; 0.94; 3.75; 4.08; 4.89 and 5.44 ^m2 . In further exemplary embodiments, sieve assemblies having virtually any total screening area can be obtained by appropriately selecting the size of the screen subassemblies and the total number of screen subassemblies.

In FIG. 75 and 76 show various embodiments in which alternative strategies may be used to combine screen elements to form screen assemblies. For example, in FIG. 75 shows a system including a first set 702 and a second set 704 of crossbars. The crossbars of the first set 702 of the crossbars may be substantially parallel to each other. Likewise, the cross members of the second plurality 704 may be substantially parallel to each other. In addition, the first set of crossbars can be made essentially perpendicular to the second set 704 of the crossbars. Thus, the first set 702 and the second set 704 of crossbars form a rectangular lattice frame.

Instead of connecting the screen subassemblies together (e.g., subassemblies 760 of Fig. 62A, subassemblies 860 of Fig. 67A, etc.) using latches (e.g., latches 42 of Fig. 3, latches 142 of Fig. 60, latches 242 of Fig. 63, etc.) to obtain sieve nodes (for example, sieve node 10 in Fig. 1, sieve node 410 in Fig. 47, sieve node 510 in Fig. 58, etc.), sieve nodes can be obtained by attaching screen sub-assemblies to crossbars 702 and 704. In this example, FIG. 75 sieves shown

- 46 039521 subassemblies 706a, 706b, 706c, 706d and 706e attached to the rectangular areas formed by the trellis frame formed by the first set 702 and the second set 704 of crossbars. Additional screen subassemblies may also be attached to additional open areas, such as open areas 708a, 708b, etc., of the screen frame of FIG. 75.

In FIG. 76 shows another embodiment in which the sieve elements can be attached directly to the plate structure 752 without the need to first attach the sieve elements to the subgrids. In this example, a plate 752 may be provided having a plurality of windows 753a, 753b, 753c, and 753d. The windows 753a-753d may be formed in the plate structure 752 by removing portions of the material of the plate 752 so that the windows 753a-753d include respective lattice frames 754a, 754b, 754c, and 754d. The lattice frames 754a, 754b, 754c, and 754d may serve as structures that may provide support for screen elements that may be attached thereto. Thus, the lattice frames 754a, 754b, 754c, and 754d may function in the same manner as the sub-arrays of other embodiments disclosed above. Windows 753a-753d are shown as an exemplary embodiment of the concept. In other embodiments, the plate structure 752 may have many more windows, which may be located close together so that a screen assembly having a larger open area can be obtained, as discussed above in connection with other embodiments.

In FIG. 76A shows screen elements 786 configured to be directly attached to a perforated plate 780, according to one embodiment. In this embodiment, plate 780 may be a metal plate that has been mechanically perforated to remove material to form holes 782a, 782b, 782c, etc. In this example, openings 782a, 782b, and 782c, etc. are rectangular holes. In other embodiments, holes of various shapes may be provided. The plate 780 may be configured to be attached to a support structure 783. The support structure 783 may be a metal or plastic frame having a plurality of holes 784a, 784b, 784c, etc. Openings 782a, 782b, and 782c may be configured to accommodate multiple screen elements 786 of the same size.

In this example, sieve element 786 may be a 1x6 sieve element, which may be similar to sieve elements 516 and 616. A sieve assembly may be obtained by attaching a plurality of sieve elements 786 to plate 780. holes 782a, 782b and 782c as indicated by arrows 788a, 788b and 788c. The screen elements 786 can be attached to the plate 780 by gluing the edges of the screen elements 786 to the respective edges of the openings 782a, 782b and 782c. Alternatively, screen elements 786 may be cast into plate 780 by inserting them into openings 782a, 782b, 782c, etc. and pouring thermosetting material around their perimeter. In an alternative embodiment, the screen elements 786 may be sized specifically so that the screen elements 786 can snap into place in the openings 782a, 782b, and 782c and be held in place by compressive forces generated by the edges of the openings 782a, 782b, 782c, etc. .d.

In FIG. 76B shows screen elements configured to be directly attached to a corrugated perforated plate, according to one embodiment. In this example, plate 880 may be corrugated. Plate 880 may be configured to attach to support structure 783 (eg, see FIG. 76A). In this regard, plate 880 may have a plurality of flat surfaces 882a, 882b, 882c, and so on. Flat surfaces 882a, 882b, 882c, etc. may be separated by projecting structural elements 884a, 884b, etc. Protruding structural elements 884a, 884b, etc. may include respective flat surfaces 886a, 886b, etc., as well as respective sloped surfaces 888a, 888b, 888c, 888d, etc. Each of the flat surfaces 882a, 882b, 882c, etc. may include perforated holes as discussed above in connection with FIG. 76A. Likewise, protrusions 884a, 884b, etc. may include perforated holes on respective flat surfaces 886a, 886b, etc. Likewise, protrusions 884a, 884b, etc. may include perforated holes on respective sloped surfaces 888a, 888b, 888c, 888d, etc.

Each of the holes on flat surfaces 882a, 882b, 882c, etc., on flat surfaces 886a, 886b, etc. and on sloped surfaces 888a, 888b, 888c, 888d, etc. may be configured to accommodate sieve elements, such as sieve element 786, shown, for example, in FIG. 76A. As discussed above, the sieve elements 786 can be attached to the holes of the corrugated plate 880 by gluing. Similarly, the screen elements 786 can be cast into the corrugated plate 880 by placing them in holes and pouring thermosetting material around their perimeter. Likewise, screen elements 786 may snap into holes and be held in place by compressive forces.

In FIG. 76C shows a frame 980 having pockets for accommodating screen elements, according to one embodiment. In this example, the support structure 980 may be a thermoplastic molded frame. The support structure may be a single injection molded piece having a thickness 981 and may be configured to include a plurality of holes or pockets 982. In other embodiments, the support structure 980 may be a metal frame. The thickness 981 can be from about 0.125 inches (~3.175 mm) to about 2 inches (~50.8 mm). In this example, pockets 982 are rectangular openings. In other embodiments, other shaped pockets may be provided. The pockets 982 may include edges 984 which may be configured to accommodate the edges of the screen element 786. As shown in FIG. 76C, the screen element can be placed over the pockets 982 and can be attached to the edges 984 by adhesive. Similarly, as discussed above with reference to FIG. 76A and 76B, screen element 786 may be cast into support structure 980 by placing screen elements 786 in pockets 982 and pouring thermoset material around the perimeter of screen element 786 to form a bond between the edges of screen element 786 and edges 984 of pockets 982. Similarly, screen elements 786 can snap into holes and be held in place by compressive forces.

The embodiments of FIG. 75 and 76-76C demonstrate that many different screen element support structures can be provided, in addition to the sub-array structures discussed above with respect to FIGS. 3-4, 10, 10A, 11, 11A, 22, 22A, 23-24D, 34, 35, 49-57A, 59-63A, 64-65A, 67-68A and 71-72C. The supporting structure must provide sufficient mechanical and thermal stability of the screening elements. The embodiments shown in FIG. 75 and 76A-76C may also provide a wider choice of materials used in the creation of screening elements. In some embodiments, it may be preferable to attach the sieve elements to the subarray structures using laser welding, as discussed in more detail above. In this regard, some designs of sublattices (for example, some of the embodiments shown in Figs. 3-4A, 10, 10A, 11, 11A, 22, 22A, 23-24D, 34, 35, 49-57A, 65A, 67-68A and 71-72C) may have material properties that complement the material properties of the screen element.

For embodiments in which the sieve elements are to be bonded to the sub-array structures using laser welding, the sieve elements must be optically transparent while the sub-array structures must have optical properties that absorb electromagnetic radiation. Thus, laser light can pass through the sieve element and can be absorbed by the optically absorbing material of the sub-array structure. The electromagnetic radiation absorbed by the sublattice structure generates heat, which locally melts the material of the sublattice structure. Upon cooling, a bond is formed between the sieve element and the subgrid structure. The need to have an optically transparent sieve element imposes restrictions on the composition of materials used to create sieve elements. In this regard, glass fiber, which is transparent, can be used as a reinforcing filler. However, other fillers such as carbon fiber should not be used as it is not transparent.

In the embodiments of FIG. 75-76C, joining methods other than laser welding may be used, such as bonding, as discussed above. Thus, the use of joining methods that are not based on laser welding removes the limitation that the screen elements must be optically transparent. In this regard, a wider choice of materials can be used to create screening elements, such as the aforementioned carbon fibers. Filler materials are generally used to enhance the strength properties of the screen element material, however, the presence of filler materials and other additives tend to degrade the material's cut, abrasion and tear resistance properties. Thus, depending on the support structure, the screen element may require more or less filler material. Therefore, certain material properties such as cut, abrasion and tear resistance can be improved in situations requiring less filler material. For example, higher temperatures (eg >54°C for mining operations, >90°C for oil and gas operations) typically require more filler to increase the strength of the material. However, in situations involving cooler temperatures and stronger support structures, less filler may be required. In such situations, material properties such as cut, abrasion and tear resistance can be improved.

There are many ways to create screening units using support structures in the embodiments shown in FIG. 75-76C. For example, screen elements 786 may be attached to the support structures shown in FIG. 75-76C, using automated processes such as the use of robotic devices to create screening units. In addition, although screening units obtained using sublattice designs (such as those shown in Figs. 3-4A, 10, 10A, 11, 11A, 22, 22A, 23-24D, 34, 35, -63A, 64 to 65A, 67 to 68A and 71 to 72C) can be interchangeable and removable, some sieve assemblies can be permanently or semi-permanently attached to the screens. For example, screening units made using support structures shown, for example, in FIG. 75-76 may be bolted or welded to the screen in a semi-one-piece or one-piece design.

Alternatively, the embodiments shown in FIG. 75-76C, can also be made with the possibility of removing and replacing the components of the screens.

Many of the subarray embodiments disclosed above have positioning elements 444 and fusible rods 476 and 478 (eg, see FIGS. 49, 59, 51, 52-55, 57, 59-65, 68, and 71-71B). Likewise, many of the screen elements disclosed above have positioning holes 424 and 524 and hollow pockets 472 (eg, see FIGS. 45A-45E, 46, 48B, 48C, 66B, 66C, and 70A). In accordance with the embodiments disclosed above, the sieve elements are aligned with the sub-arrays by inserting the positioning elements 444 (sub-arrays) into the positioning holes 424 and 524 (sieve elements) so that the fusible rods 476 and 478 (sub-arrays) are inside the hollow pockets 472 (sieve elements). The screen elements can then be attached to the subgrids by fusing (eg, using laser welding, heat reflow, etc.) the fusible rods 476 and 478 to fuse with hollow pockets 472 to form a bond.

However, the presence of positioning holes 424 and 525 in the screen elements can create problems in the manufacture of screen elements using methods including thermoplastic injection molding. In this regard, the presence of positioning holes 424 and 524 i can reduce the flow of thermoplastic material during the injection molding process.

In FIG. 77A, 77B, and 77C show new embodiments where positioning holes (eg, 424 and 525 in FIGS. 45A-45E, 46, 48B, 48C, 66B, 66C, and 70A) are omitted from the screen elements. In accordance with new embodiments, shown for example in FIG. 77A, 77B, and 77C, the hollow pockets and fusible rods can be modified to play the role previously played by the positioning holes and positioning elements, respectively, thus eliminating the need for separate positioning holes in the sieve elements and positioning elements in the subgrids. In FIG. 77A shows an embodiment of a fusible rod 544 having sharp corners 546a and 546b. In FIG. 77B shows an embodiment of a hollow pocket having first 574a and second 574b approximately flat interior surfaces. The hollow pocket 572 is slightly larger than the fusible rod 544 so that the shape of the hollow pocket 572 allows the fusible rod 544 to enter when the sieve element containing the hollow pocket 572 is positioned over the subgrid containing the fusible rod 544, as shown in FIG. 77C.

In FIG. 77C shows an embodiment in which the hollow pocket 572 acts as the positioning hole and the fusible rod 544 acts as the positioning element. In this regard, the sharp points 546a and 546b of the fusible rod 572 come into contact with the corresponding approximately flat inner surfaces 574a and 574b of the hollow pocket 572. The size and shape of the fusible rod 544 ensures that the fusible rod 544 is in close contact with the inner surfaces 546a and 546b of the hollow pocket 572. According to this design, there is little freedom for relative movement between hollow pocket 572 and fusible rod 544. Thus, as shown in FIG. 77C, the sieve element can be properly aligned with the subarray due to the small alignment tolerance between the fusible rod 544 and the hollow pocket 572. As a result, the need for separate positioning elements and positioning holes is eliminated.

Embodiments of the present invention disclosed herein, including screening elements and screening units, can be configured for use in various vibrating screens and parts thereof, including screens for wet and dry screening applications, screens having tiered decks and/or multiple screening baskets, and screens having various means of attaching screens, such as tension mechanisms (bottom and top mounting), compression mechanisms, clamping mechanisms, magnetic mechanisms, etc. For example, the sieve assemblies disclosed in the present invention may be configured to be mounted on vibrating screens disclosed in US Pat. Nos. 7,578,394; 5332101; 6669027; 6,431,366 and 6,820,748. Indeed, screen assemblies disclosed herein may include: side portions or connecting bars including U-shaped elements configured to receive top-mounted tension elements, for example, as disclosed in the US patent No. 5332101; side portions or link bars including finger receiving holes configured to receive bottom mounted tensioners, such as as disclosed in US Pat. No. 6,669,027; side members or connecting bars for compression load, for example as disclosed in US Pat. No. 7,578,394; or may be configured to be mounted and loaded on multi-level screens, such as those disclosed in US Pat. No. 6,431,366. No. 12/460200 (currently US Pat. No. 8,443,984), including technologies disclosed therein related to guide assemblies and technologies related to finished panels. In addition, the screen assemblies and screen elements can be configured to be included in the pre-screening technologies (e.g., compatible with screen structures and configurations) disclosed in the patent application.

- 49 039521

US No. 12/051658 (currently - US patent No. 8439203). US Patents No. 7578394; 5332101; 4882054; 4857176; 6669027; 7228971; 6,431,366 and 6,820,748 and U.S. Patent Applications No. 12/460,200 (currently U.S. Patent No. 8,443,984) and 12/051,658 (currently U.S. Patent No. 8,439,203), which, along with their related patent families and applications, and patents and patent applications referenced in these documents are expressly incorporated herein by reference.

Exemplary embodiments have been disclosed above. However, it will be obvious that various modifications and changes can be made to them without going beyond their broader nature and scope. The description and drawings are to be considered in an illustrative and not restrictive sense.

CLAIM

Claims (17)

CLAIM 1. A sieve assembly containing a support structure and a sieve element attached to the support structure, wherein the sieve element has a screening surface containing screening holes, which are elongated slots having essentially the same length L along the first direction and, in essence, , the same width W along the second direction, and the width W of the screening holes is approximately 40 mkm<W<200 μm, and the length L of the screening holes is approximately 0.7 mm<L<2 mm; and surface elements separating the screening holes, wherein the surface elements have a thickness T along the second direction of approximately 70 μm < T < 400 μm, and the sieve assembly has a screening open area of from approximately 5 to approximately 35% of the total area of the screening surface . 2. The sieve assembly of claim 1, wherein the screening surface has a screening area of about 10 to about 15% of the total area of the screening surface. 3. The sieve assembly of claim 1, wherein the screening surface has a screening area of about 15 to about 25% of the total area of the screening surface. 4. The sieve assembly of claim 1, wherein the screening surface has a screening area of about 25 to about 35% of the total area of the screening surface. 5. Sieve node according to claim 1, in which the thickness T of the surface elements is approximately 0.014 inches; and the screening area is in the range of approximately 6 to 24% of the total area of the screening surface. 6. Sieve node according to claim 1, in which the thickness T of the surface element is approximately 0.007 inches; and the screening area is in the range of approximately 10 to 28% of the total area of the screening surface. 7. Sieve node according to claim 1, in which the thickness T of the surface element is approximately 0.005 inches; and the screening area is in the range of approximately 12 to 32% of the total area of the screening surface. 8. Sieve node according to claim 1, in which the thickness T of the surface elements is approximately 0.003 inches; screening area is in the range of approximately 13 to 33% of the total area of the screening surface. 9. The sieve assembly of claim 1, wherein the sieve element comprises a first plurality of reinforcing elements spatially aligned with respective support elements of the first support mesh of the support structure. 10. The sieve assembly according to claim 9, wherein the sieve element further comprises a second plurality of reinforcing elements configured to be spatially aligned with respective support elements of the second support mesh of the support structure, wherein the support elements of the second support mesh are located between respective adjacent support elements of the first support mesh. so that the linear density of the reference elements of the combined first and second reference grids is greater than the linear density of the reference elements of the first reference grid. 11. Sieve node according to claim 1, in which the thickness T of the surface elements is approximately 356 microns; - 50 039521 the length L of the screening holes is approximately 1.9 mm; and the screening area varies from about 6 to 24%, while the width W of the screening holes varies from about 45 to 180 µm. 12. Sieve node according to claim 1, in which the thickness T of the surface elements is approximately 178 microns; the length L of the screening holes is approximately 1.2 mm; and the screening area varies from about 10 to 28%, while the width W of the screening holes varies from about 45 to 180 µm. 13. Sieve node according to claim 1, in which the thickness T of the surface element is approximately 127 microns; the length L of the screening holes is approximately 0.8 mm; and the screening area varies from about 12 to 32%, while the width of the screening holes varies from about 45 to 180 microns. 14. Sieve node according to claim 1, in which the thickness T of the surface elements is approximately 76 microns; the length L of the screening holes is approximately 0.7 mm; and the screening area varies from about 13 to 33%, while the width of the screening holes varies from about 45 to 180 microns. 15. The sieve assembly of claim 1, wherein the sieve element is a single injection molded thermoplastic piece. 16. The screen assembly of claim 1, wherein the support structure further comprises a plurality of subgrids bonded together to form a screen assembly having a screening surface that has a total screening area in the range of about 0.4 to 6.0 m ² . 17. The sieve assembly of claim 16, wherein the subgrids include at least one base element having locking means configured to mate with locking means of other base elements of other subgrids and thereby fasten the subgrids together, and wherein the locking means comprise latches and latch holes, and the latches include a central protruding element that engages with the latch holes to securely fasten the subgrids together.