EA042381B1 - INJECTION MOLDED SCREENING DEVICE AND METHOD - Google Patents

Description

Cross-reference to related applications

This application is a continuation in part of U.S. Patent Application No. 13/800826, filed March 13, 2013, which claims the benefit of U.S. Provisional Application No.

61/652039, filed May 25, 2012, and U.S. Provisional Application No. 61/714,882, filed October 17, 2012.

The technical field to which the invention belongs

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

Prerequisites for the creation of the invention

Screening of material involves the use of vibratory screening machines. Vibratory screening machines provide the ability to excite the installed sieve, so that the materials located on the sieve can be separated to the desired level. Materials larger than the specified size are separated from materials smaller than the specified size. Over time, the screens wear out and need to be replaced. Thus, the sieves are replaceable.

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

Replacement screen assemblies are typically made of metal or heat-cured polymer. The material and configuration of the replaceable screens are specific to screening applications. For example, due to their relative durability and ability to screen fine particles, metal screens are often used in wet applications in the oil and gas industry. However, traditional heat-cured polymer screens (eg, molded polyurethane screens) are not as durable and would likely not withstand the rigors of these wet applications and are often used in dry applications such as mining.

Fabrication of heat-cured polymer sieves is relatively complex, time consuming and error prone. Typical heat-set polymer screens that are used in conjunction with vibrating screeners are made by combining separate fluids (e.g., polyester, polyether, and hardener) that are chemically reacted, and then allowing the mixture to solidify over a period of time in the mold. When making sieves with fine openings, for example, from about 43 microns to about 100 microns, this process can be extremely complex and time consuming. Moreover, in order to create fine openings in the sieve, the channels in the molds through which the liquid passes must be very small (eg, on the order of 43 microns), and often the liquid does not reach all the cavities in the mold. As a result, complex procedures are often performed that require special attention to pressures and temperatures. Since one relatively large sieve is made in the mold (for example, two feet by three feet or more), one defect (for example, a hole, i.e., a place where liquid has not entered) will spoil the entire sieve. Heat-set polymer screens are typically made by molding the entire screen assembly as one large screening portion, and the screen assembly may have openings ranging from about 43 µm to about 4000 µm. The screen surface of conventional heat-cured polymer screens typically has a uniform flat configuration.

The heat-set polymer screens are relatively flexible and are often attached to the vibrating screener using tension members that pull the side edges of the heat-set polymer screen away from each other and secure the bottom surface of the heat-set polymer screen against the surface of the shaker screen. cars. To prevent deformation under tension, heat-set polymer assemblies can be formed using aramid fibers that extend in the direction of tension (see, for example, US Pat. No. 4,819,809). When a compressive force is applied to the side edges of typical heat-cured polymer screens, they will warp or bend, thus rendering the screening surface relatively inefficient.

Unlike heat-set polymer screens, metal screens are rigid and can be compressed or stretched on a vibrating screener. Metal screen assemblies are often made from a variety of metal components. The manufacture of metal screen assemblies typically involves the manufacture of a screening material, often three layers of woven wire mesh; manufacturing a metal base plate with a hole and connecting the screening material with a metal base plate with a hole. The layers of wire cloth can be finely woven with openings ranging from about 30 µm to about 4000 µm. The entire screening surface of conventional metal assemblies is typically a relatively uniform flat configuration or a relatively uniform corrugated configuration.

- 1 042381

Critical to the screening performance of screen assemblies (assemblies of heat-cured polymer and metal assemblies) for vibrating screening machines 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 block, the chemical properties of the block components and the ability of the block to work. at different temperatures and under different conditions. Disadvantages of traditional metal assemblies include insufficient structural stability and durability of the screen surface formed by the layers of woven wire mesh, clogging (blockage of the screen holes with particles) of the screen surface, the weight of the overall structure, the time and expense associated with the manufacture or purchase of each of the component elements, and the time and assembly costs. Because screen manufacturers often order wire cloth externally and often purchase it from weavers or wholesalers, quality control is extremely difficult and problems often arise with the wire cloth. Defective wire cloth can lead to sieve performance problems and constant monitoring and testing is required.

One of the biggest problems with traditional metal assemblies is clogging. A new metal screen may initially have a relatively large open screening area, but over time, as the screen is exposed to particulates, the screen holes clog (i.e. clog) and the open screening area and the efficiency of the screen itself decline relatively quickly. For example, a 140 mesh screen assembly (having three layers of screen cloth) may have an initial screening area of 20-24%. However, as the sieve is used, the open sieving area can be reduced by 50% or more.

Conventional metal screen assemblies also lose large amounts of open screening area due to their design, which includes binders, backing plates, plastic sheets holding layers of wire cloth together, and so on.

Another major problem with conventional metal assemblies is screen life. Traditional metal assemblies typically do not fail due to wear, but instead fail due to fatigue. Those. woven wire cloth wires often actually break due to the up and down movement they are subjected to during vibration loading.

The disadvantages of traditional heat-cured polymer screens also include insufficient structural stability and durability. Additional disadvantages include an inability to withstand compression-type loading and an inability to withstand high temperatures (e.g., typically a heat-set polymer screen will begin to fail or experience efficiency problems at temperatures above 130°F, especially screens with fine openings, e.g., from about 43 µm to about 100 µm). Also, as discussed above, fabrication is complex, time consuming and error prone. Also, the molds used to make heat-cured polymer screens are expensive and any defect or the slightest damage to the mold will ruin the entire mold and require replacement, which can lead to costly downtime in the manufacturing process.

Another disadvantage of both conventional metal screens and heat-cured polymer screens is the limited number of screen surface configurations available. Existing screening surfaces are made with relatively uniform hole sizes over the entire area and a relatively uniform surface configuration over the entire area, regardless of whether the screening surface is flat or undulating.

The conventional polymer sieves referred to in U.S. Provisional Application No. 61/652039 (also referred to therein as conventional polymer sieves, existing polymer sieves, conventional polymer sieves, or conventional polymer sieves) refer to the conventional heat-cured polymer sieves described in U.S. Provisional Application No. 61/714882, and conventional heat-set polymer screens described herein (also referred to herein and in U.S. Provisional Application No. 61/714882 as traditional heat-set polymer screens, existing screens heat-set polymer, typical heat-set polymer screens, or conventional heat-set polymer screens). Accordingly, the conventional polymer sieves referred to in U.S. Provisional Application No. 61/652,039 are similar to the conventional heat-set polymer sieves referred to herein and in U.S. Provisional Application No. 61/714,882, and may be made with extremely small screen openings (as described here and in U.S. Provisional Application No. 61/714882), but have all the disadvantages (as described here and in U.S. Provisional Application No. 61/714882) regarding conventional heat-set polymer screens, including insufficient structural strength and durability, failure to withstand compression-type loading, failure to withstand high temperatures, and complex, time-consuming, error-prone manufacturing methods.

There is a need for versatile and improved sieve elements, sieve assemblies, methods

- 2 042381 manufacturing screen elements and screen assemblies and methods for screening materials for vibrating screening machines, which include the use of materials obtained by injection molding (for example, thermoplastics) having improved mechanical and chemical properties.

The essence of the invention

The present invention is an improvement on existing screen assemblies and methods for screening and manufacturing screen assemblies and parts thereof. The present invention provides extremely versatile and improved screen elements, screen assemblies, methods for making screen elements and screen assemblies, and methods for screening materials for vibratory screening machines, which include the use of injection molded materials having improved properties, including mechanical and chemical properties. . In some embodiments of the present invention, a thermoplastic is used as the injection molded material. The present invention is not limited to injection molded thermoplastic 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 screen elements are securely attached to the screen element structures. The grid elements are fastened together to form a screen assembly that has a screening surface containing a plurality of screen elements. The use of injection molded screen elements with the various embodiments described herein includes, inter alia, varying screen surface configurations; a quick and relatively easy screen assembly to manufacture and a combination of exceptional mechanical, chemical and electrical properties of the screen assembly including strength, wear resistance and chemical resistance.

Embodiments of the present invention include screen assemblies that are capable of having relatively large open screening areas while having structurally stable small screen openings for use in vibratory screening of fine particles. 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, one inch by two inches, two inches by three inches, etc. ) for practical assembly of the complete screening surface of the sieve assembly (for example, two feet by three feet, three feet by four feet, etc.). Making small screen holes for fine particle screening applications requires very small injection molded structural members that actually form the screen holes. These structural elements are injection molded to form them together with the screen element design. It is important to note that the structural elements are small enough (for example, in some applications they can be on the order of approximately 43 microns in the width of the screening surface) to provide an effective total open screening area and form part of the entire screen element structure that is large enough (for example, two inches by three inches) for practical assembly of a relatively large completed screening surface (eg two feet by three feet).

In one embodiment of the present invention, the thermoplastic material is injection molded to form the screen elements. In the past, thermoplastics have not been used to make vibrating screens with fine openings (e.g., from about 43 µm to about 1000 µm) because it is extremely difficult, if not impossible, to injection mold a thermoplastic into one relatively large vibrating screen structure having small openings, and obtain the open screening area required for competitive vibratory screening applications.

In accordance with an 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 large vibrational forces; contains a plurality of injection molded screen elements which, due to their relatively small size, can be made with extremely small openings (having sizes up to about 43 microns); eliminates the need for wire cloth; is easy; recyclable; it is easy and simple to assemble; can be made in many different configurations, including the presence of screen openings of various sizes throughout the sieve and the presence of various configurations of the screening surface, for example, various combinations of flat and undulating areas; and can be made from application-specific materials or nanomaterials. Moreover, each sieve assembly can be custom-made for a specific application and can be easily and simply manufactured with different sizes of openings and various configurations depending on the specifications provided by the end user. Embodiments of the present invention can be applied in various application conditions, including wet and dry application conditions, and can be applied in various industries. The present invention is not limited to the oil and gas industry and

- 3 042381 mining industry, it can be used in any industry that needs to separate materials using vibrating screening machines, including pulp and paper, chemical, pharmaceutical and other industries.

In an exemplary embodiment of the present invention, a screen assembly is provided that substantially improves screening of materials using an injection molded thermoplastic screen element. A plurality of screen elements made from injection molded thermoplastic polymer are securely attached to the screen element structures. The grid elements are fastened together to form a screen assembly that has a screening surface containing a plurality of screen elements. Each sieve element and each grid element may have different shapes and configurations. The thermoplastic injection molding of the individual sieve elements allows accurate fabrication of the screening holes, which can be up to about 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 screening machine. Moreover, the assembled screen elements to form the completed screen assembly are strong enough not only to withstand vibration loading, but also to withstand the forces required to attach the screen assembly to the vibrating screening machine, including heavy compression loads, loads tension and/or pressing load. Moreover, the openings in the grid elements structurally support the screen elements and transmit vibrations from the vibrating screening machine to the elements forming the screening openings, thus optimizing the screening efficiency. The screen elements, grid elements and/or any other component of the screen assembly may include nanomaterials and/or glass fibers which provide durability and strength in addition to other advantages.

According to an exemplary embodiment of the present invention, there is provided a screen assembly having a screen element comprising a screen element screening surface with a sequence of screen holes, and a screen element comprising a plurality of elongated structural elements forming a screen frame having screen openings. The sieve element covers at least one of the lattice holes and is attached to the upper surface of the lattice element. A plurality of independent screen elements are fastened together to form a screen assembly, and the screen assembly has a continuous screening surface of the screen assembly having a plurality of screening surfaces of the screen element. The sieve element contains essentially parallel end parts and essentially parallel side edge parts, essentially perpendicular to the end parts. The sieve element further comprises a first support element for the sieve element and a second support element for the sieve element extending orthogonally to the first support element for the sieve element. The first support element for the screen element extends between the end portions and is approximately parallel to the side edge portions. The second support element for the screen element extends between the side edge portions and is approximately parallel to the end portions. The sieve element contains a first sequence of reinforcing elements substantially parallel to the side edge portions and a second sequence of reinforcing elements substantially parallel to the end portions. The screening surface of the sieve element includes elements of the sieve surface forming screening holes. The end portions, the side edge portions, the first and second support members, and the first and second sequences of reinforcing members provide structural stability to the screen surface members and the screen openings. The sieve element is formed in one piece made of injection molded thermoplastic.

Screening holes can be rectangular, square, round and oval or any other shape. The screen surface elements can run parallel to the end portions and form screening holes. The screen surface features may also extend perpendicular to the end portions and form screen openings. Various combinations of rectangular, square, round and oval screening holes (or other shapes) can be combined together 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 openings. The screening holes may be elongated slots having a distance of about 43 microns to about 4000 microns between the inner surfaces of adjacent elements of the screen surface. In some embodiments, the screen holes may have a distance of about 70 microns to about 180 microns between the inner surfaces of adjacent elements of the screen surface. In other embodiments, the screen openings may have a distance of about 43 microns to about 106 microns between the inner surfaces of adjacent elements of the screen surface. In embodiments of the present invention, the screen openings may have a width and length, wherein the width may be from about 0.043 mm to about 4 mm and the length may be from about 0.086 mm to about 43 mm. In some embodiments, the width to length ratio may be from about 1:2 to about

1:1000.

A plurality of screen elements of various sizes may be combined to form a screen assembly support structure for the screen elements. Alternatively, a single screen element may be injection molded from a thermoplastic or otherwise formed to form the entire screen support assembly for a plurality of individual screen elements.

In embodiments in which a plurality of lattice elements are used, the first lattice element may comprise a first base element having a first anchor that mates with a second anchor of the second base element of the second lattice element, wherein the first and second anchors hold the first and second lattice elements together. The first fastener may be a latch and the second fastener may be a latch hole, wherein the latch snaps into the latch hole and securely fastens the first and second lattice elements together.

The first and second support elements for the sieve element and the end portions of the sieve element may comprise a sieve element attachment arrangement configured to mate with the grid element attachment arrangement. The screen element attachment arrangement may comprise elongated attachment elements, and the screen element attachment arrangement may include attachment holes that mate with the elongated attachment elements securely attaching the screen element to the screen element. Part of the elongated fasteners can be configured to pass through the fastening holes of the sieve element and slightly above the screening surface of the sieve element. The attachment holes may comprise a tapered channel, or may simply comprise an opening without any cone. Part of the elongated fasteners above the screening surface of the sieve element can be melted and can fill the conical channel, attaching the sieve element to the lattice element. Alternatively, the portion of the elongated fasteners that extends through and over the opening in the screening surface of the screen element may be melted such that it forms a bead on the screening surface of the screen element and attaches the screen element to the screen element.

The elongated structural elements may comprise substantially parallel lattice element end elements and substantially parallel lattice element side elements substantially perpendicular to the lattice element end elements. The elongated structural elements may further comprise a first lattice element support element and a second lattice element support element extending orthogonally to the first lattice element support element. The first supporting element of the lattice element may extend between the end elements of the lattice element and may be approximately parallel to the side elements of the lattice element. The second supporting element of the lattice element may extend between the side elements of the lattice element and may be approximately parallel to the end elements of the lattice element and substantially perpendicular to the edge elements of the lattice element.

The lattice frame may include first and second lattice frames forming the first and second lattice openings. The sieve elements may comprise first and second sieve elements. The lattice element may have a ribbed portion and a base portion. The first and second grating frames may comprise first and second corner surfaces that peak at the ribbed portion and extend downward from the peak portion to the base portion. The first and second screen elements may span the first and second corner surfaces, respectively.

According to an exemplary embodiment of the present invention, there is provided a screen assembly having a screen element comprising a screen element screening surface with a sequence of screen holes, and a screen element comprising a plurality of elongated structural elements forming a screen frame having screen openings. The sieve element covers at least one lattice opening and is attached to the upper surface of the lattice element. A plurality of screen members are fastened together to form a screen assembly, and the screen assembly has a continuous screen assembly screen surface comprised of a plurality of screen element screen surfaces. The sieve element is a single piece made from injection molded thermoplastic.

The screen element may comprise substantially parallel end portions and substantially parallel side edge portions substantially perpendicular to the end portions. The sieve element may further comprise a first sieve element support element and a second sieve element support element extending orthogonally to the first sieve element support element. The first support member for the screen element may extend between the end portions and may be approximately parallel to the side edge portions. The second support member for the screen element may extend between the side edge portions and may be approximately parallel to the end portions. The sieve element may comprise a first series of reinforcing elements substantially parallel to the side edge portions and a second series of reinforcing elements substantially parallel to the end portions. The sieve element may comprise elongated sieve surface elements extending parallel to the end portions and forming screening openings.

The end portions, the side edge portions, the first and second support members, the first and second strings of reinforcing members may provide structural stability to the screen surface members and the screen openings.

The first and second sequences 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 support elements of the screen element. The end portions and side edge portions and the first and second support members of the screen element may form four rectangular areas. The first series of reinforcing elements and the second series of reinforcing elements may form a plurality of rectangular support grids within each of the four rectangular areas. The screen openings may have a width of from about 43 µm to about 4000 µm between the inner surfaces of each of the elements of the sieve surface. In some embodiments, the screen openings may have a width of from about 70 µm to about 180 µm between the inner surfaces of each of the elements of the sieve surface. In other embodiments, the screen openings may have a width of from about 43 µm to about 106 µm between the inner surfaces of each of the sieve surface features. In embodiments of the present invention, screen openings may have a width of from about 0.043 mm to about 4 mm and a length of from about 0.086 mm to about 43 mm. In some embodiments, the width to length ratio may be from about 1:2 to about 1:1000.

The screen elements may be flexible.

The end elements of the lattice element, the side elements of the lattice element, and the first and second supporting elements of the lattice element may form eight rectangular openings of the lattice. The first sieve element may span the four holes of the grid and the second sieve member may span the remaining four holes.

The central part of the screening surface of the sieve element may bend slightly under load. The lattice element may be substantially rigid. The grid element may also be a single piece made from injection molded thermoplastic. At least one of the end elements of the lattice element and the side elements of the lattice element may include fasteners made with the possibility of mating with fasteners of other lattice elements, while the fasteners can be latches and latch holes that snap and securely fasten the lattice elements together.

The lattice element may comprise substantially parallel triangular end portions, triangular middle portions substantially parallel to the triangular end portions, first and second middle supports substantially perpendicular to the triangular end portions and extending between the triangular end portions, first and second base supports substantially perpendicular triangular end portions and extending between the triangular end portions, and a central rib substantially perpendicular to the triangular end portions and extending between the triangular end portions. The first edge of the triangular end portions, the triangular middle portions, and the first middle support, the first base support, and the central rib may form a first top surface of the lattice element having a first series of lattice openings. The second edge of the triangular end portions, the triangular middle portions and the second middle leg, the second base leg and the central rib may form a second top surface of the grating element having a second series of grating openings. The first top surface may extend from the central rib to the first base leg and the second top surface may extend from the central rib to the second base leg. The first and second screen elements may span a first sequence and a second sequence of screen openings, respectively. The first edges of the triangular end parts, the triangular middle parts, the first middle support, the first base support, and the central rib may comprise a first grid element attachment arrangement configured to securely mate with the first screen element attachment arrangement of the first screen element. The second edges of the triangular end portions, the triangular middle portions, the second middle support, the second base support, and the central rib may comprise a second grid element attachment arrangement configured to securely mate with the second screen element attachment arrangement of the second screen element. The first and second screen element attachment arrangements may comprise elongated attachment elements, and the first and second screen element attachment arrangements may include attachment holes that mate with the elongated attachment elements, thereby securely attaching the first and second screen elements to the first and second grid elements, respectively. . Part of the elongated fasteners may pass through the fastening holes of the sieve element and slightly above the first and second screening surfaces of the sieve element.

Each of the first and second screen elements may comprise substantially parallel end portions and substantially parallel side edge portions substantially perpendicular to the end portions. Each of the first and second screen elements may comprise a first screen element support and a second screen element support extending orthogonally to the first screen element support, wherein the first screen element support extends between the end portions and is approximately parallel to the side edge portions. , the second support element for the screen element extends between the side edge portions and may be approximately parallel to the end portions. Each of the first and second screen elements may comprise a first series of reinforcing elements substantially parallel to the side edge portions and a second series of reinforcing elements substantially parallel to the end portions. Each of the first and second screen elements may include elongated screen surface elements extending parallel to the end portions and forming screening openings. The end portions, the side edge portions, the first and second support members, the first and second strings of reinforcing members may provide structural stability to the screen surface members and the screen openings.

One of the first and second base supports may include fasteners that fasten a plurality of lattice elements together, while the fasteners may be latches and latch holes that snap and securely fasten the lattice elements together.

The sieve assembly may include first, second, third and fourth sieve elements. The first grid hole sequence may be eight holes defined by the first edge of the triangular end portions, the triangular middle portions, and the first middle leg, the first base leg, and the center rib.

The second grid hole sequence may be eight holes defined by the second edge of the triangular end portions, the triangular middle portions, the second middle leg, the second base leg, and the center rib. The first sieve element may cover four grid holes of the first grid hole sequence, and the second screen element can cover the remaining four grid holes of the first grid hole sequence. The third sieve element may span the four grid holes of the second grid aperture sequence, and the fourth screen element may span the remaining four grid holes of the second grid aperture sequence. The central part of the first, second, third and fourth screening surfaces of the sieve element may bend slightly under load. The grid element may be substantially rigid and may be a single piece made from an injection molded thermoplastic.

According to an exemplary embodiment of the present invention, there is provided a screen assembly having a screen element comprising a screen element screening surface with screen holes and a screen element including a screen frame with screen holes. The sieve element covers the openings of the grid and is attached to the surface of the grid element. A plurality of screen elements are fastened together to form a screen assembly, and the screen assembly has a continuous screen assembly screening surface that includes a plurality of screen element screen surfaces. The sieve element is a part made of injection molded thermoplastic.

The screen assembly may also comprise a first screen element made from injection molded thermoplastic and a second screen element made from injection molded thermoplastic, and the screen frame may comprise first and second screen frames forming a first screen opening and a second screen opening. The grating element may comprise a ribbed portion and a base portion, first and second grating frames comprising first and second corner surfaces that peak at the ribbed portion and extend downward from the peak portion to the base portion. The first and second screen elements may span the first and second corner surfaces, respectively. The first and second corner surfaces may comprise a grid element attachment arrangement configured to securely mate with the screen element attachment arrangement. The screen element attachment arrangement may comprise elongated attachment elements, and the screen element attachment arrangement may include openings that mate with the elongated attachment elements, thereby securely attaching the screen elements to the screen element.

The grid element may be substantially rigid and may be a single piece made from an injection molded thermoplastic. The base portion portion may include first and second fasteners that attach the grating element to the third and fourth fasteners of another grating element. The first and third fasteners may be latches, and the second and fourth fasteners may be latch holes. The latches can click into the latches holes and securely fasten the grid element together with another grid element.

The grid members may form a concave structure and the continuous screening surface of the screen assembly may be concave. The screen elements may form a flat structure and the continuous screening surface of the sieve assembly may be flat. The screen elements may form a convex structure and the continuous screening surface of the sieve assembly may be convex.

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The screen assembly may be configured to form a predetermined concave shape by a compressive force applied by the vibrating screen assembly compressive assembly to at least one side member of the vibrating screen assembly when placed in the vibrating screen machine. The predetermined concave shape may be determined according to the shape of the surface of the vibrating sieving machine. The screen assembly may have a mating surface mating the screen assembly to the surface of the vibrating screening machine, wherein the mating surface may be rubber, metal (e.g., steel, aluminum, etc.), composite material, plastic material, or any other suitable material. The screen assembly may include a docking surface configured to interact with the docking surface of the vibrating screening machine such that the screen assembly is guided to a fixed position on the vibrating screening machine. The docking surface may be formed in part of at least one lattice element. The mating surface of the screen assembly may be a depression formed in a corner of the screen assembly or a depression formed approximately in the middle of a side edge of the screen assembly. The screen assembly may have an arcuate surface configured to mate with the concave surface of the vibratory screening machine. The screen assembly may be of a substantially rigid structure that does not substantially bend during attachment to the vibrating screening machine. The screen assembly may include a screen assembly mating surface formed such that it forms a predetermined concave shape under the action of a compressive force applied by the vibratory screening machine element. The mating surface of the sieve assembly may be shaped such that it interacts with the mating surface of the vibrating screening machine so that the sieve assembly can be guided to a predetermined location on the vibrating screening machine. The sieve assembly may include a load band attached to an edge surface of the screen assembly grating element, wherein the load band may be configured to distribute the load over the entire surface of the sieve assembly. The screen assembly may be configured to form a predetermined concave shape under the action of a compressive force applied by the compressing element of the vibrating screen machine to the load band of the vibrating screen assembly. The screen assembly may have a concave shape and may be configured to bend and form a predetermined concave shape under the action of a compression force applied by the vibrating screening machine element.

The first set of lattice members may form center support frame assemblies having the first attachment arrangement. The second set of lattice members may form a first end support frame assembly having a second attachment arrangement. The third set of lattice members may form a second end support frame assembly having a third attachment arrangement. The first, second, and third attachment arrangements may attach the first and second end support frames to the center support assemblies. The side edge surface of the first end support frame assembly may form a first end of the screen assembly. The side edge surface of the second end support frame arrangement may form the second end of the screen assembly. An end surface of each of the first and second end support frame assemblies and the center support frame assembly may collectively form the first and second side surfaces of the completed screen 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 screen assembly may include attachments configured to engage at least one of the bonding strip and/or the load distributing strip. The lattice elements may include side surfaces such that when the individual lattice elements are fastened together to form the first and second end support frame assemblies and the center support frame assembly, the first and second end support frame assemblies and the center support frame assembly form a concave shape. . The lattice elements may comprise side surfaces shaped such that when the individual lattice elements are fastened together to form the first and second end support frame assemblies and the center support frame assembly, the first and second end support frame assemblies and the center support frame assembly form a curved shape.

The screen elements can be attached to the screen elements using at least one of a mechanical arrangement, a bonding agent, heat swaging and/or ultrasonic welding.

According to an exemplary embodiment of the present invention, there is provided a screen element having a screen element screen surface with screen surface elements forming a series of screen holes; a pair of substantially parallel end portions; a pair of substantially parallel side edge portions substantially perpendicular to the end portions; a first support element for the sieve element; a second sieve element support element extending orthogonally to the first sieve element support element, wherein the first sieve element support element extends between the end portions and approximately

- 8 042381 is parallel to the side edge parts, the second supporting element for the sieve element extends between the side edge parts and is approximately parallel to the end parts and essentially perpendicular to the side edge parts; a first sequence of reinforcing elements substantially parallel to the side edge portions; and a second series of reinforcing elements substantially parallel to the end portions. The screen surface elements run parallel to the end portions. The end parts, the side edge parts, the first and second support elements, the first and second series of reinforcing elements provide structural stability to the screen surface elements and the screening holes, and the screen element is a single piece made from an injection molded thermoplastic.

According to an exemplary embodiment of the present invention, there is provided a screen element having a screen element screen surface with screen surface elements forming a series 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 part made of injection molded thermoplastic.

The sieve element may also have a first support element for the sieve element; a second screen element support extending orthogonally to the first screen element support, wherein the first screen element support extends between the end portions and is approximately parallel to the side edge portions, the second screen element support extends between the side edge portions and is approximately parallel to the end portions parts; a first sequence of reinforcing elements substantially parallel to the side edge portions; and a second series 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 may also be configured to extend perpendicular to the end portions. The end portions, the side edge portions, the first and second support members, the first and second strings of reinforcing members may provide structural stability to the screen surface members and the screen openings.

The screen element may also have a screen element attachment arrangement molded together with the screen element and configured to mate with the grid element attachment arrangement. A plurality of screen elements may form a screen assembly, and the screen assembly may have a continuous screen assembly screen surface that includes a plurality of screen element screen surfaces.

According to an exemplary embodiment of the present invention, there is provided a method for manufacturing a screen assembly for screening materials, which includes determining performance specifications of the screen assembly for the screen assembly; determining a screening hole requirement for the screen element based on performance specifications of the screen assembly, the screen element comprising a screening surface of the screen element having screening holes; determining a screen configuration based on performance specifications of the screen assembly, wherein the screen configuration includes having screen elements located in at least one of a flat configuration and/or a non-planar configuration; injection molding of sieve elements from thermoplastic material; manufacture of a grid element capable of supporting the screen elements, wherein the grid element has a grid frame with grid holes, wherein at least one screen element covers at least one grid hole and is attached to the upper surface of the grid element, the upper surface of each grid element contains at least one of a flat surface and a non-planar surface that contains the sieve elements; attaching the sieve elements to the lattice elements; fastening together a plurality of screen assemblies to form screen end frames and screen center frames; attaching the end screen frames to the center screen frames to form a screen frame structure; attaching a first bonding strip to a first end of the screen frame structure; and attaching a second bonding strip to a second end of the screen frame structure to form a screen assembly, the screen assembly having a continuous screening surface of the screen assembly consisting of a plurality of screening surfaces of the screen element.

The performance specifications of the sieve assembly may include at least one of the dimensions, material requirements, screening open area, cut-off point, and required screening power. The handle can be attached to the connecting strip. A label may be affixed to the bonding strip, the label including a description of the performance of the screen assembly. At least one of the sieve element and the grid element may be a single piece made from an injection molded thermoplastic. The thermoplastic material may contain a nanomaterial. The lattice element may comprise at least one base element having fasteners that mate with the fasteners of the remaining base elements of the remaining lattice elements and fasten the lattice elements together. The fasteners may be latches and latch holes that snap and securely fasten the lattice elements together.

- 9 042381

According to an exemplary embodiment of the present invention, there is provided a method for manufacturing a screen assembly for screening materials by forming a screen element from an injection molded thermoplastic material, the screen element comprising a screen element screening surface having screening holes; manufacturing a screen element that supports the screen element, wherein the screen element has a screen frame with screen openings, the screen element enclosing at least one screen opening; attaching the screen element to the top surface of the screen element; and fastening together a plurality of screen assembly to form a screen assembly, wherein the screen assembly has a continuous screening surface of the screen assembly made of the plurality of screening surfaces of the screen element. The method may also include attaching a first bonding strip to a first end of the screen assembly and attaching a second bonding strip to a second end of the screen assembly. The first and second connecting strips may connect the grid elements together. The connecting strip may be configured to distribute the load across all first and second ends of the screen assembly. The thermoplastic material may contain a nanomaterial.

According to an exemplary embodiment of the present invention, there is provided a method for screening material by attaching a screen assembly to a vibrating screen machine, the screen assembly comprising a screen element having a series of screen holes defining a screen element screening surface, and a grating element comprising a plurality of elongated structural elements forming a lattice frame having lattice openings. The sieve elements cover the openings of the grid and are attached to the upper surface of the grid element. A plurality of lattice elements are fastened together to form a screen assembly. The sieve assembly has a continuous screening surface of the sieve assembly, consisting of a plurality of screening surfaces of the sieve element. The sieve element is a single piece made from injection molded thermoplastic. The material is screened using the sieve assembly.

According to an exemplary embodiment of the present invention, there is provided a method for screening material, comprising attaching a screen assembly to a vibrating screen machine and forming a concave top screening surface of the screen assembly. The sieve assembly contains a sieve element having a sequence of screening holes forming the screening surface of the sieve element, and a lattice element containing a plurality of elongated structural elements forming a lattice frame having lattice openings. The sieve elements cover the openings of the grid and are attached to the upper surface of the grid element. A plurality of screen elements are fastened together to form a screen assembly, and the screen assembly has a continuous screening surface of the screen assembly consisting of a plurality of screening surfaces of the screen element. The sieve element is a single piece made from injection molded thermoplastic. The material is screened using the sieve assembly.

According to an exemplary embodiment of the present invention, there is provided a screen assembly comprising a screen element having a first engagement arrangement; and a lattice member assembly having a second clutch arrangement. The first clutch arrangement and the second clutch arrangement may be different materials. At least one of the first clutch arrangement and the second clutch arrangement is excitable so that the screen element and the grid element can be fastened together. The sieve element is a single piece made from injection molded thermoplastic.

The first engagement arrangement may be a plurality of cavities on the bottom surface of the screen element and the second engagement arrangement may be a plurality of fused strips on the top surface of the screen element. The sieve element is formed by microforming and has screen openings from about 40 µm to about 1000 µm. The cavities may be elongated cavities. The fused strips may have a height that slightly exceeds the depth of the cavities. The depth of the cavities may be approximately 0.05 inches and the height of the raft strips is approximately 0.056 inches. The fused strips may have a width that is slightly less than the width of the cavities.

The sieve element may contain thermoplastic polyurethane. The lattice element may contain nylon. The screen assembly may include additional screen elements and screen elements fastened together, with a plurality of lattice elements fastened together. The sieve element may have a plurality of screen openings, which are elongated slots with a width and length, with screen openings ranging from about 43 µm to about 1000 µm wide between the inner surfaces of each sieve surface element. The screen element can be attached to the grid element by laser welding. The weld between the screen element and the screen element may comprise a mixture of materials from the screen element and the screen element.

According to an exemplary embodiment of the present invention, there is provided a screen assembly comprising a screen element including a screening surface

- 10 042381 sieve element having a sequence of screening holes, and a grating element containing a plurality of elongated structural elements forming a grating frame having grating openings. The sieve element covers at least one of the lattice holes and is attached to the upper surface of the lattice element. A plurality of independent screen elements are fastened together to form a screen assembly, and the screen assembly has a continuous screening surface of the screen assembly having a plurality of screening surfaces of the screen element. The sieve element contains essentially parallel end parts and essentially parallel side edge parts, essentially perpendicular to the end parts. The sieve element further comprises a first support element for the sieve element and a second support element for the sieve element extending orthogonally to the first support element for the sieve element, wherein the first support element for the sieve element extends between the end parts and is approximately parallel to the side edge parts, the second support element for the screen element extends between the side edge portions and is approximately parallel to the end portions. The sieve element contains the first sequence of reinforcing elements, essentially parallel to the side edge parts, the second sequence of reinforcing elements, essentially parallel to the end parts. The sifting surface of the sieve element contains elements of the sieve surface forming screening holes. End parts, side edge parts, first and second supporting elements, first and second sequences of reinforcing elements provide structural stability of the screen surface elements and screening holes. The sieve element is a single piece made from injection molded thermoplastic. The sieve element contains a plurality of cavities on the lower surface of the sieve element. The lattice element contains a plurality of alloy strips on the upper surface of the lattice element. A plurality of fused strips are configured to dock with a plurality of cavities.

The screen holes may be elongated slots with a width and length, with the width of the screen holes ranging from about 43 microns to about 1000 microns between the inner surfaces of each element of the screen surface. The plurality of fused strips may have a height that slightly exceeds the depth of the plurality of cavities. The height of the plurality of alloy strips may be approximately 0.056 inches. The depth of the plurality of cavities may be approximately 0.050 inches. Each of the plurality of cavities may have a width that is slightly greater than the width of each of the plurality of alloy strips. The plurality of alloy strips can be configured such that, when melted, a portion of the plurality of alloy strips fills the width of the plurality of cavities. The material of the sieve element may be fused to the material of the screen element. The sieve element may be configured to allow the laser to pass through the sieve element and contact the plurality of alloy strips. The laser can melt a portion of the plurality of alloy strips by fusing the sieve element to the grating element.

The grid element may be a single piece made from an injection molded thermoplastic. The sieve element may comprise a thermoplastic polyurethane material. The thermoplastic polyurethane may be at least one of polyether thermoplastic polyurethane and/or polyester thermoplastic polyurethane. The lattice element may comprise a nylon material. The alloy strips may contain at least one of carbon and/or graphite material. The screen element may comprise a sieve element centralizer arrangement configured to center the sieve element on the screen element. The sieve element may include a plurality of conical return channels on the top surface of the sieve element along side edge portions and end portions between the centralizer openings for centralizer arrangement. Alloy strips and cavities can be made of various materials.

The grid frame may comprise first and second grid frames defining the first and second grid openings, wherein the screen elements comprise the first and second screen elements. The screen element may comprise a ribbed portion and a base portion, the first and second screen frames comprise first and second corner surfaces that peak at the ribbed portion and extend downward from the peak portion to the base portion, wherein the first and second sieve elements surround the first and second corner surfaces. surfaces, respectively. The screen assembly may include a secondary support frame enclosing at least a portion of each grate opening.

According to an exemplary embodiment of the present invention, there is provided a screen assembly comprising a screen element comprising a screen element screening surface having a series of screening holes and a plurality of cavities on the bottom surface of the screen element; and a grating element comprising a plurality of elongated structural elements forming a lattice frame having lattice openings, and a plurality of alloy strips on the upper surface of the lattice element. The sieve element covers at least one lattice opening and is attached to the upper surface of the lattice element by fusing a plurality of alloy strips with a plurality of cavities. A plurality of screen members are fastened together to form a screen assembly, and the screen assembly has a continuous screen assembly screen surface comprised of a plurality of screen element screen surfaces. The sieve element represents

- 11 042381 is one piece made from injection molded thermoplastic. The sieve element is configured to allow the laser to pass through the sieve element and contact the plurality of alloy strips.

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

The lattice element may comprise substantially parallel triangular end portions, triangular middle portions substantially parallel to the triangular end portions, first and second middle supports substantially perpendicular to the triangular end portions and extending between the triangular end portions, first and second base supports substantially perpendicular triangular end portions and extending between the triangular end portions, and a central rib substantially perpendicular to the triangular end portions and extending between the triangular end portions, wherein the first edge of the triangular end portions, the triangular middle portions, the first middle support, the first base support, and the central rib form the first top surface of the grille element having the first series of grille openings, and the second edge of the triangular end portions, the triangular middle portions, the second middle support, the second base support, and the central rib form the second upper the surface of a grating element having a second series of grating openings, wherein the first top surface descends from the central rib to the first base support, the second top surface descends from the central rib to the second base support. The first and second screen elements may span a first sequence and a second sequence of screen openings, respectively.

In exemplary embodiments of the present invention, a method for manufacturing a screen assembly is provided, comprising laser welding a screen element of a first material to a screen element of a second material; and fastening the plurality of grid members together to form a screen assembly. The first material and the second material are different materials. The first material and the second material are fused together at the laser welding points.

The screen assembly may have a first engagement arrangement on the bottom surface of the screen element and the screen element has a second engagement arrangement on the top surface of the screen element. The first clutch arrangement may be a plurality of cavities and the second clutch arrangement may be a plurality of alloy strips. The plurality of cavities may be configured to mate with the plurality of alloy strips.

The method for manufacturing a screen assembly may include centering the screen element on the screen element by means of centering holes in the screen element and centering extensions on the upper surface of the screen element. The method of manufacturing a sieve assembly may include passing a laser through a sieve element to contact a plurality of alloy strips. The method for manufacturing a screen assembly may include laser melting a portion of the plurality of alloy strips. The method for manufacturing a screen assembly may include melting a portion of the first material with one of the heat generated by the laser and the heat transferred from the melted portions of the plurality of alloy strips. The method for making the screen assembly may include removing the laser so that the molten portion of the first material and the molten portion of the fused strips mix and return to a solid state.

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

Brief description of graphic materials

In FIG. 1 is an isometric view of an assembled screen according to an exemplary embodiment of the present invention.

In FIG. 1A is an enlarged view of an isolated portion of the sieve assembly shown in FIG. 1.

In FIG. 1B is a bottom isometric view of the screen assembly shown in FIG. 1.

In FIG. 2 shows a top isometric view of a sieve element according to an exemplary embodiment of the present invention.

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

In FIG. 2B is a bottom isometric view of the sieve element shown in FIG. 2.

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

In FIG. 2D is an enlarged plan view of a highlighted portion of the sieve element shown in FIG. 2.

In FIG. 3 shows an isometric plan view of an end grating element in accordance with

- 12 042381 an exemplary embodiment of the present invention.

In FIG. 3A is an isometric bottom view of the end grating shown in FIG. 3.

In FIG. 4 shows a top isometric view of a central grill element in accordance with an exemplary embodiment of the present invention.

In FIG. 4A is a bottom isometric view of the central grate shown in FIG. 4.

In FIG. 5 shows an isometric plan view of a connecting strip according to an exemplary embodiment of the present invention.

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

In FIG. 6 is an isometric view of a portion of a screen assembly according to an exemplary embodiment of the present invention.

In FIG. 6A is an exploded view of a portion of the assembly shown in FIG. 6.

In FIG. 7 is a plan view of the screen assembly shown in FIG. 1.

In FIG. 7A is an enlarged cross-sectional view of the portion A-A of the screen assembly shown in FIG. 7.

In FIG. 8 is an isometric plan view of an assembly of screens partially covered with screen elements, in accordance with an exemplary embodiment of the present invention.

In FIG. 9 is an exploded isometric view of the sieve assembly shown in FIG. 1.

In FIG. 10 is an exploded isometric view of an end screen showing screen elements before being attached to an end screen, in accordance with an exemplary embodiment of the present invention.

In FIG. 10A is an isometric view of the end grille shown in FIG. 10 having sieve elements attached thereto.

In FIG. 10B is a plan view of the end grating shown in FIG. 10A.

In FIG. 10C is a cross-sectional view of the B-B portion of the end grille shown in FIG. 10A.

In FIG. 11 is an exploded isometric view of a central screen showing screen elements before being attached to the center screen, in accordance with an exemplary embodiment of the present invention.

In FIG. 11A is an isometric view of the central lattice element shown in FIG. 11 having sieve elements attached thereto.

In FIG. 12 is an isometric view of a vibrating screening machine having screen assemblies with concave screening surfaces mounted thereon, in accordance with an exemplary embodiment of the present invention.

In FIG. 12A is an enlarged isometric view of the discharge end of the vibratory screening machine shown in FIG. 12.

In FIG. 12B is a front view of the vibrating screening machine shown in FIG. 12.

In FIG. 13 is an isometric view of a single screen vibratory screen machine having screen assemblies with concave screen surfaces mounted thereon, in accordance with an exemplary embodiment of the present invention.

In FIG. 13A is a front view of the vibrating screening machine shown in FIG. 13.

In FIG. 14 is a front view of a vibrating screening machine having two separate concave screening surfaces with preformed screen assemblies mounted on a vibrating screening machine, in accordance with an exemplary embodiment of the present invention.

In FIG. 15 is a front view of a vibratory screening machine having a single screening surface with a preformed screen assembly installed on the vibrating screening machine, in accordance with an exemplary embodiment of the present invention.

In FIG. 16 is an isometric view of a portion of an end support frame assembly according to an exemplary embodiment of the present invention.

In FIG. 16A is an exploded isometric view of a portion of the end support frame assembly shown in FIG. 16.

In FIG. 17 is an isometric view of a portion of a center support frame assembly in accordance with an exemplary embodiment of the present invention.

In FIG. 17A is an exploded isometric view of a portion of the center support frame assembly shown in FIG. 17.

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

In FIG. 19 is an isometric plan view of a flat screen assembly according to an exemplary embodiment of the present invention.

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

In FIG. 21 is an isometric view of an assembled sieve having pyramid-shaped lattice members in accordance with an exemplary embodiment of the present invention.

In FIG. 21A is an enlarged view of the screen assembly section D shown in FIG. 21.

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

In FIG. 22A is a bottom isometric view of the pyramidal-shaped end grille shown in FIG. 22.

In FIG. 23 is a top isometric view of a pyramidal shaped central lattice element in accordance with an exemplary embodiment of the present invention.

In FIG. 23A is a bottom isometric view of the pyramid-shaped central lattice element shown in FIG. 23.

In FIG. 24 is an isometric view of a portion of a pyramid-shaped assembly according to an exemplary embodiment of the present invention.

In FIG. 24A is an exploded isometric view of a portion of the pyramid-shaped assembly shown in FIG. 24.

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

In FIG. 24C is an isometric view of the pyramidal shaped end grill shown in FIG. 24B having sieve elements attached thereto.

In FIG. 24D is an exploded isometric view of a pyramidal shaped center screen showing screen elements before being attached to the pyramid shaped center screen, in accordance with an exemplary embodiment of the present invention.

In FIG. 24E is an isometric view of the pyramid-shaped central lattice element shown in FIG. 24D having sieve elements attached thereto.

In FIG. 25 is a plan view of an assembly of screens having pyramid-shaped mesh elements in accordance with an exemplary embodiment of the invention.

In FIG. 25A is a cross-sectional view of the C-C portion of the screen assembly shown in FIG. 25.

In FIG. 25B is an enlarged view of the C-C portion shown in FIG. 25A.

In FIG. 26 is an exploded isometric view of a screen assembly having pyramid-shaped and flat-shaped assembly parts, in accordance with an exemplary embodiment of the present invention.

In FIG. 27 is an isometric view of a double screen vibratory screen machine having concave screen assemblies mounted thereon, the screen assemblies comprising pyramid shaped and flat shaped assembly parts, in accordance with an exemplary embodiment of the present invention.

In FIG. 28 is an isometric plan view of an assembled screen having pyramidal and flat screen elements without screen elements, in accordance with an exemplary embodiment of the present invention.

In FIG. 29 is a top isometric view of the screen assembly shown in FIG. 28 with the screen elements partially covered by the screen elements.

In FIG. 30 is a front view of a double screen vibrating screen machine having concave screen assemblies mounted thereon, the screen assemblies comprising pyramid-shaped and flat-shaped screen elements, in accordance with an exemplary embodiment of the present invention.

In FIG. 31 is a front view of a single screen vibratory screen machine having a concave screen surface assembly mounted thereon, the screen assembly comprising pyramid-shaped and flat-shaped screen elements, in accordance with an exemplary embodiment of the present invention.

In FIG. 32 is a front view of a double screen vibrating screen machine having preformed screen assemblies with flat screen surfaces mounted thereon, the screen assemblies comprising pyramid shaped and flat shaped screen elements, in accordance with an exemplary embodiment. of the present invention.

In FIG. 33 is a front view of a vibrating single screen sieving machine having a preformed sieve assembly with a flat screen surface mounted thereon, the sieve assembly comprising pyramid shaped and flat shaped screen elements as shown in as an example, an embodiment of the present invention.

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

In FIG. 35 is an enlarged view of the highlighted portion E of the end grating shown in FIG. 34.

In FIG. 36 is an isometric view of a screen assembly having pyramid-shaped lattice members in a portion of the screen assembly, in accordance with an exemplary embodiment of the present invention.

In FIG. 37 shows a block diagram of the manufacture of a screen assembly in accordance with an exemplary embodiment of the present invention.

In FIG. 38 shows a block diagram of the manufacture of a screen assembly in accordance with an exemplary embodiment of the present invention.

In FIG. 39 is an isometric view of a vibrating sieve machine having a single sieve assembly with a flat sieving surface mounted thereon, with part of the vibrating machine cut off, thereby showing the sieve assembly, in accordance with an exemplary embodiment of the present invention.

In FIG. 40 shows a top isometric view of a single screen element in accordance with an exemplary embodiment of the present invention.

In FIG. 40A shows a top isometric view of a sieve element pyramid in accordance with an exemplary embodiment of the present invention.

In FIG. 40B is an isometric plan view of the four sieve element pyramids shown in FIG. 40A.

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

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

In FIG. 40E shows a top isometric view of a screen element structure in accordance with an exemplary embodiment of the present invention.

In FIG. 40F is a front view of the screen element structure shown in FIG. 40E.

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

In FIG. 44 shows an isometric plan view of a pre-screen assembly with pre-screens in accordance with an exemplary embodiment of the present invention.

In FIG. 44A is a top isometric view of the pre-screen assembly shown in FIG. 44 in accordance with an exemplary embodiment of the present invention.

In FIG. 45 is a plan view of a screen element over a portion of a screen element in accordance with an exemplary embodiment of the present invention.

In FIG. 45A is an exploded side view of a cross-section A-A showing a screen element above a portion of the screen element shown in FIG. 45.

In FIG. 45B is a cross-sectional side view A-A of the sieve element and part of the screen element shown in FIG. 45 before attaching the screen element to the screen element, in accordance with an exemplary embodiment of the present invention.

In FIG. 45C is an enlarged view of the portion A shown in FIG. 45V.

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

In FIG. 45E is an enlarged view of the section B shown in FIG. 45D.

In FIG. 46 shows a cross-sectional side view of a portion of a screen element and a portion of a screen element according to an exemplary embodiment of the invention.

In FIG. 47 shows a top isometric view of a portion of a screen assembly in accordance with an exemplary embodiment of the present invention.

In FIG. 48 shows a top isometric view of a sieve element in accordance with an exemplary embodiment of the present invention.

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

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

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

In FIG. 49 shows an isometric plan view of the end grating element in accordance with

- 15 042381 an exemplary embodiment of the present invention.

In FIG. 49A is a bottom isometric view of the end grille shown in FIG. 49.

In FIG. 50 shows a top isometric view of a central grill element in accordance with an exemplary embodiment of the present invention.

In FIG. 50A is a bottom isometric view of the central lattice element shown in FIG. 50.

In FIG. 51 is an exploded isometric view of an end screen showing screen elements before being attached to an end screen, in accordance with an exemplary embodiment of the present invention.

In FIG. 51A is an isometric view of the end grille shown in FIG. 51 having sieve elements attached thereto.

In FIG. 52 is an exploded isometric view of a central screen showing screen elements before being attached to the center screen, in accordance with an exemplary embodiment of the present invention.

In FIG. 52A is an isometric view of the central lattice element shown in FIG. 52 having sieve elements attached thereto.

In FIG. 53 is a plan isometric view of a pyramid-shaped end grille according to an exemplary embodiment of the present invention.

In FIG. 53A is a bottom isometric view of the pyramid-shaped end grate shown in FIG. 53.

In FIG. 54 shows a top isometric view of a pyramidal shaped central lattice element in accordance with an exemplary embodiment of the present invention.

In FIG. 54A is a bottom isometric view of the pyramid-shaped central lattice element shown in FIG. 54.

In FIG. 55 is an exploded isometric view of a pyramid-shaped end screen showing screen elements before being attached to the pyramid-shaped end screen, in accordance with an exemplary embodiment of the present invention.

In FIG. 55A is an isometric view of the pyramid-shaped end lattice member shown in FIG. 55 having sieve elements attached thereto.

In FIG. 56 is an exploded isometric view of a pyramidal shaped center screen showing screen elements before being attached to the pyramid shaped center screen, in accordance with an exemplary embodiment of the present invention.

In FIG. 56A is an isometric view of the pyramid-shaped central lattice element shown in FIG. 56 having sieve elements attached thereto.

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

In FIG. 57A is an enlarged view of portion A of the end grill shown in FIG. 57.

Detailed description

Like reference numbers designate like parts throughout the drawings.

Embodiments of the present invention provide a screen assembly that includes injection molded screen elements that mate with a screen element. The plurality of grid members are securely attached to each other to form a vibrating screen assembly that has a continuous screening surface and is capable of being used on a vibrating screening machine. The entire screen assembly is designed to withstand the harsh load conditions it encounters during installation and operation on the vibrating screening machine. Injection molded screen elements offer many advantages in screen assembly and vibratory screening applications. In some embodiments, implementation of the present invention, the elements of the sieve are made of thermoplastic material by injection molding. In some embodiments of the present invention, the screen elements may have a first engagement arrangement configured to mate with a second engagement arrangement on the screen element. The first and second clutch arrangements may include different materials and may be configured such that the screen elements can be laser welded to the screen element. The first clutch arrangement may be a plurality of cavities and the second clutch arrangement may be a plurality of alloy strips, which may be configured to

- 16 042381 laser melting. The screen elements may contain thermoplastic polyurethane, which may be polyester or polyether based. Embodiments of the present invention include screen elements attached to screen elements by a hardened mixture of separate materials. Embodiments of the present invention include methods for making a screen assembly by fusing screen elements with screen elements using laser welding and bonding a plurality of screen elements together to form a screen assembly.

Embodiments of the present invention provide injection-molded screen elements that are of a practical size and configuration for making vibrating screen assemblies and for use in vibrating screening applications. Several important aspects have been taken into account in the configuration of the individual sieve elements. Screen elements are provided that are: optimally sized (large enough to effectively assemble a complete screen assembly, but still small enough to be injection molded (microformed in some embodiments) extremely small structures forming screen holes while avoiding curing (i.e. solidification of the material in the form before the complete filling of the form)); have an optimal open screening area (the opening and supporting openings are sized to a minimum size to increase the total open area used for screening while maintaining in some embodiments the very small screening openings required for proper separation of materials according to the specified standard) ; have durability and strength, can work in different temperature ranges; are chemically resistant; have a stable design; are extremely versatile in screen assembly processes; and are configurable in custom configuration for specific applications.

Embodiments of the present invention provide screen elements that are manufactured using extremely precise injection molding. The larger the sieve element, the easier it is to assemble the complete vibrating sieve assembly. Simply put, fewer pieces need to be put together. However, the larger the screen element, the more difficult it is to injection mold extremely small structures, i.e. structures that form screening holes. It is important to minimize the size of the screen opening structures in order to maximize the number of screen openings on an individual screen element and therefore optimize the open screening area for the screen element and thus the entire screen assembly. In some embodiments, screen elements are provided that are large enough (e.g., one inch by one inch, one inch by two inches, two inches by three inches, etc.) to practical assembly of a complete screen assembly screen surface (e.g., two feet by three feet, three feet by four feet, etc.). A relatively small size (eg, one inch by one inch, one inch by two inches, two inches by three inches, etc.) is large enough during microforming of extremely small features (eg, features up to 43 microns). The larger the size of the entire screen element and the smaller the size of the individual structural elements forming the screening holes, the more the injection molding process is prone to errors such as solidification. Thus, the size of the sieve elements must be practical for making a sieve assembly, yet small enough to eliminate problems such as curing during microforming of extremely small designs. The dimensions of the screen elements may vary depending on the material used for injection molding, the size of the screen openings required and the total open screen area required.

Open screening area is essential for vibrating screen assemblies. The average usable open screening area (i.e. the actual open area after taking into account the metalwork of the support members and connecting materials) for traditional wire screen assemblies from 100 to 200 mesh can be in the range of 16%. Specific embodiments of the present invention (eg, screen assemblies with the designs described herein having screen openings of 100 to 200 mesh) provide screen assemblies in a similar range having similar actual open screening areas. However, in practice traditional sieves clog rather quickly, which leads to a fairly rapid decrease in the actual open screening area. It is not uncommon for traditional metal screens to become clogged within the first 24 hours of use and their actual open screening area is reduced by 50%. Conventional wire assemblies also often fail as a result of the wire being subjected to vibrational forces that cause a bending load 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 real open screen area) and rarely fail due to the stability of screen assembly design and configuration, including sieve elements and lattice element designs. In fact, screen assemblies according to embodiments of the present invention are extremely

- 17 042381 long service life and can withstand long periods of time under heavy load. The screen assemblies of the present invention have been tested for months under severe conditions without failure or plugging, while traditional wire assemblies have been tested under similar conditions and plugged and failed in days. As discussed in more detail herein, conventional heat-curable assemblies cannot be used in these applications.

In embodiments of the present invention, a thermoplastic is used to make injection molded screen elements. Unlike heat-set polymers, which often contain liquid materials that chemically interact and solidify under the influence of temperature, the use of thermoplastics is often simpler and can be provided, for example, by melting a homogeneous material (often in the form of solid granules) and then injection molding of molten material. Not only are the physical properties of thermoplastics optimal for vibratory screening applications, but the use of thermoplastic fluids also allows for easier manufacturing processes, especially during microforming of parts as described herein. The use of thermoplastic materials in the present invention provides excellent flexibility and flexural fatigue strength and is ideal for parts subjected to intermittent heavy load or continuous heavy load encountered by vibrating screens used on vibrating screeners. Since vibrating screeners are subject to movement, the low friction coefficient of injection molded thermoplastic materials provides optimum wear characteristics. Moreover, the wear resistance of some thermoplastics is superior to that of many metals. Also, the use of thermoplastics as described herein provides an optimal material for making latches due to its stiffness and extensibility characteristics. The use of thermoplastics in embodiments of the present invention also provides resistance to stress cracking, aging, and extreme atmospheric conditions. The heat distortion temperature of thermoplastics is in the 200°F range. With the addition of glass fibers, it will increase from about 250°F to about 300°F or higher, as well as increase the stiffness when measured by the flexural modulus from about 400,000 psi. inch to approximately 1,000,000 psi. inch. All these properties are ideal for the conditions encountered during the use of vibrating sieves on vibrating sieving machines under the harsh conditions encountered in practice.

Embodiments of the present invention may include various materials in the screen element blocks and/or screen elements depending on the desired properties of the embodiments. Thermoplastic polyurethane (TPU) can be included in embodiments of the present invention (eg screen elements) providing elasticity, transparency and oil, grease and abrasion resistance. TPU also has high shear strength. These TPU properties are advantageous when applied to embodiments of the present invention that are subjected to high vibrational forces, abrasive materials, and high required loads. Various types of TPUs may be included in the embodiments depending on the material being screened. For example, polyester-based TPUs can be included in screen assemblies used for screening with oil and/or gas because the esters provide excellent abrasion resistance, oil resistance, mechanical integrity, chemical resistance, and bond strength. Polyether TPUs can be included in mining applications where resistance to hydrolysis is important (a property of ether TPUs). Paraphenylene diisocyanate (PPDI) may be included in embodiments of the present invention. PPDI can provide high performance in various screening applications. Materials for embodiments of the present invention may be selected or determined based on a number of factors, including the performance of each material and the cost associated with the use of the materials.

In embodiments of the present invention, materials for the screen element may be selected to have high temperature tolerance, chemical resistance, hydrolysis resistance, and/or abrasion resistance. The screen elements may include materials such as TPU to provide a clean appearance to the screen elements. Clean sieve elements can effectively pass the laser through the sieve elements for laser welding purposes. The materials of the grating element may differ from the material of the sieve element. In embodiments of the present invention, the lattice elements may be made of nylon. The lattice elements may include carbon or graphite. Various materials between the screen elements and the grid elements can be bonded to each other by laser welding, which can provide a stronger bond between the screen elements and the grid elements than alternative fastening methods. Stronger attachment of the screen element to the screen element provides improved screen assembly performance under the high vibration forces of vibrating screeners and the abrasive forces that occur on the surfaces of the screen elements during screening of materials.

In FIG. 1 illustrates a sieve assembly 10 for use with vibrating sieving machines. The screen assembly 10 is shown having a plurality of screen elements 16 (see, for example, FIGS. 2 and 2A-2D) mounted on the screen element structures. The lattice element structures include a plurality of independent end lattice element blocks 14 (see, for example, Fig. 3) and a plurality of independent central lattice element blocks 18 (see, for example, Fig. 4), which are fastened together to form a lattice frame having openings 50 grids. Each element 16 of the sieve covers four openings 50 of the grid. Although the sieve element 16 is shown as a block covering four grid holes, the sieve elements can be provided in larger or smaller blocks. For example, a sieve element that is about one-fourth the size of the sieve element 16 may be provided so that it will enclose one opening 50 of the grid. Alternatively, a sieve element that is approximately twice the size of the sieve element 16 can be provided so that it spans all eight openings of the grid of the grid element 14 or 18. Other sized grids can also be provided. For example, grate blocks may be provided that have two grate openings per block, or one large grate may be provided for the overall design, i.e. one grate design for the entire screen assembly. In FIG. 1, a plurality of independent screen elements 14 and 18 are fastened together to form a screen 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 element. Each sieve element 16 is an injection molded thermoplastic part.

In FIG. 1A is an enlarged view of a portion of a screen assembly 10 having a plurality of end screens 14 and center screens 18. As discussed below, end screens 14 and center screens 18 may be fastened together to form a screen assembly. Screen elements 16 are shown attached to end screens 14 and center screens 18. The size of the screen assembly can be changed by fastening more or fewer screens together to form a screen assembly. Once installed in the vibrating sieving machine, the material can be fed to the 10 sieve assembly. 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 openings 50 of the grid, thus separating the material from that which is too large. for passing through the holes of the sieve elements 16 of the sieve.

In FIG. 1B shows a bottom view of the screen assembly 10 so that the grid holes 50 can be seen under the screen elements. Connecting strips 12 are attached to the sides of the lattice frame. Connecting strips 12 can be attached to hold the parts of the assembly together to form the frame of the lattice. The connecting strips 12 may include fasteners that are attached to the fasteners on the side elements 38 of the blocks (14 and 18) of the lattice element or the fasteners on the base element 64 of the pyramidal blocks (58 and 60) of the lattice element. Connecting strips 12 may be provided to improve the stability of the grid frame and may distribute compression loads if the screen assembly is installed on a vibrating screener using compression, for example, using compression assemblies as described in US Pat. No. 7,578,394 and US Patent Application No. 12/460200. Connecting strips can also be provided that include U-shaped elements or holes accommodating pins for pulling from below or above the vibrating sieving machine, for example, see the mounting structures described in US patents No. 5332101 and 6669027. Screen elements and the screen members are securely fastened together as described herein so that even under tension, the screen assembly screen surface and screen assembly retain their structural integrity.

The screen assembly shown in Fig. 1 is slightly concave, i.e. the bottom and top surfaces of the sieve assembly have a slight curve. The lattice elements 14 and 18 are made in such a way that, when they are assembled together, this predetermined bend is achieved. Alternatively, the screen assembly may be flat or convex (see, for example, FIGS. 19 and 20). As shown in FIG. 12, 12A, 13 and 13A, the screen assembly 10 may be mounted on a vibratory screening machine having one or more screening surfaces. In one embodiment, the screen assembly 10 may be mounted on the vibrating screener by placing the screen assembly 10 on the vibrating screener such that the connecting strips contact the end or side members of the vibrating screener. A compressive force is then applied to the bonding strip 12. The connecting strips 12 distribute the load from the compressive force across the screen assembly. The screen assembly 10 may be configured to bend and deform into a predetermined concave shape when a compression force is applied to the connecting strip 12. The amount of deformation and the range of concavity can be changed according to the use, the applied compression force, and the shape of the bottom support of the vibrating screening machine. . Compression sieve 10 assembly concave

- 19 042381 form during installation in the vibrating screening machine provides many advantages, such as easy and simple installation and removal, capture and centering of materials to be screened, etc. Additional benefits are listed in US Pat. No. 7,578,394. Centering material flows on the 10 sieve assembly prevents material from falling off the screen surface and possibly contaminating previously separated materials and/or creating maintenance problems. For larger volumes of material flow, the sieve assembly 10 can be placed under greater compression, thus increasing the arc size of the sieve assembly 10. The larger arc size in the sieve assembly 10 provides greater material retention capacity of the sieve assembly 10 and prevents excessive spillage of material from the edges of the sieve assembly 10. The screen assembly 10 may also be configured to deform into a convex shape when compressed, or to remain substantially flat when compressed or pressed. Inclusion of the connecting strips 12 in the sieve 10 assembly ensures that the compression load from the vibrating screening machine is distributed throughout the sieve 10 assembly. The screen assembly 10 may include guide recesses in the connecting strips 12 to assist in guiding the screen assembly 10 into place during installation on a vibratory screening machine having guides. Alternatively, the screen assembly may be mounted on a vibratory screening machine without connecting strips 12. In an alternative embodiment, guide recesses may be included in the screen element blocks. US Patent Application No. 12/460200 is incorporated herein by reference and any embodiments disclosed therein may be incorporated into the embodiments of the present invention described 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 screen element includes surface elements 84 extending parallel to the end portions 20 of the screen element and forming screening holes 86. See FIG. 2D. The surface features 84 have a thickness T which may vary depending on the screening application conditions and the configuration of the screen holes 86. The thickness T can be, for example, from about 43 µm to about 100 µm depending on the required open screening area and the width W of the screen holes 86 The screening holes 86 are elongated slots having a length L and a width W which can be varied for the selected configuration. The width may be a distance of about 43 microns to about 2000 microns between the inner surfaces of each element 84 of the sieve surface. The screen holes do not have to be rectangular, but can be injection molded from thermoplastic in any shape suitable for a particular screening application, including square, round, and/or oval. For increased stability, the screen surface features 84 may include solid fibrous materials that may extend substantially parallel to the end portions 20. The fiber may be aramid fiber (or individual filaments thereof), a naturally occurring fiber, or other material having a relatively high tensile strength. US Patent No. 4,819,809 and US Patent Application No. 12/763,046 are incorporated herein by reference and, accordingly, the embodiments disclosed therein may be included in the sieve assemblies disclosed herein.

The element 16 of the sieve may include holes 24 of the attachment, made in such a way that the elongated elements 44 of the attachment of the lattice element can pass through the holes 24 of the attachment. Mounting holes 24 may include a conical channel that can be filled by melting a portion of the elongated mounting member 44 above the screening surface of the sieve member, securing the sieve member 16 to the grating member. Alternatively, the mounting holes 24 can be made without a conical channel, allowing the formation of a bead on the screening surface of the sieve element by melting a portion of the elongated mount 44 above the screening surface of the sieve element, attaching the sieve element to the lattice element. The sieve element 16 may be a single piece made from an injection molded thermoplastic. The sieve element 16 may also be a plurality of injection molded thermoplastic parts, each of which is configured to enclose one or more grid openings. The use of small injection molded thermoplastic screen elements 16 that are attached to the grid frame as described herein provides significant advantages over prior art screen assemblies. Injection molded thermoplastic screen elements 16 provide screen openings 86 having a width W of up to about 43 µm. This ensures accurate and efficient screening. The arrangement of the screen elements 16 on grid elements, which can also be injection molded from thermoplastic, allows for easy assembly of complete screen assemblies with very fine screening openings. Placing the screen elements 16 on the screen elements also provides significant variation in the overall size and/or configuration of the screen assembly 10, which can be changed by including more or less screen elements or screen elements having different shapes. Moreover, a screen assembly having screen openings of various sizes or screen openings of increasing sizes can be created by simply placing screen elements 16 with screen openings of various sizes on the screen elements and combining the screen elements into a desired 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 extending orthogonally to the first screen element support 28 and between the side edge portions 22, which is approximately parallel to the end portions 20 and substantially perpendicular to the side portions 22. The screen element may further comprise a first series of reinforcing members. 32 substantially parallel to the side edge portions 22 and a second series of reinforcing elements 34 substantially parallel to the end portions 20. End portions 20, side edge portions 22, first screen element support 28, second screen element support 30, first a series of reinforcements 32 and a second series of reinforcements 34 structurally stabilize the screen surface elements 84 and screen openings 86 during various loadings, including compression force distribution and/or vibration loading conditions.

In FIG. 3 and 3A illustrate an end grille assembly 14. The end grille assembly 14 includes parallel grille ends 36 and parallel side grilles 38 substantially perpendicular to the grille ends 36. Block 14 of the end grating element has attachments along one end element 36 of the grating element and along the side elements 38 of the grating element. The fasteners can be latches 42 and latches holes 40 so that a plurality of grating blocks 14 can be securely fastened together. The grille units can be secured together along their respective side members 38 by extending the latch 42 into the latch hole 40 until the latch 42 extensions extend beyond the latch hole 40 and the side member 38 of the grille. As the latch 42 is pushed into the latch opening 40, the drawers of the latch will be compressed together until the latch portion of each latch extends beyond the side member 38 of the grill element, ensuring that the latch portions engage with the inside of the side member 38 of the lattice member. After the latch portions are engaged within the latch opening, the side members of the lattice element of the two independent lattice elements will be adjacent to each other and fastened together. The lattice elements can be separated by applying force to the latch extensions so that the extensions move together to allow the latch portions to exit from the latch opening. Alternatively, latches 42 and latch holes 40 may be used to secure the end element 36 of the lattice element to the end element of the lattice element of another lattice element, such as the central lattice element (FIG. 4). The end grate may have a grate end 36 which does not have any fasteners. Although the fasteners shown in the drawings are latches and latch holes, alternative fasteners and alternative forms of latches and holes may be used, including other mechanical fasteners, adhesives, etc.

By making the screen frame of screen elements, which can be substantially rigid, a strong and stable screen frame and screen assembly 10 are formed. The screen assembly 10 is constructed in such a way that it can withstand a heavy load without damaging the screening surface and the supporting structure. For example, the pyramid-shaped lattice frames shown in FIG. 22 and 23 provide a very strong pyramid-based frame that supports individual sieve elements capable of screening very fine particles, having screen openings up to 43 microns. In contrast to the pyramidal embodiment of the screen assembly of the present invention described herein, existing wire mesh screen assemblies of the corrugated or pyramidal type are excessively susceptible to damage and/or deformation under heavy loading. Thus, unlike current screens, the present invention provides screen assemblies having very small and very accurate screening openings, while also providing significant structural stability and resistance to damage, thus maintaining accurate screening under various loads. The creation of a screen frame from the screen elements also allows a significant change in the size, shape and/or configuration of the sieve assembly by simply changing the number and/or type of screen elements used to create the screen frame.

The end grating unit 14 includes a first grating support element 46 extending parallel to the side grating elements 38 and a second grating element supporting element 48 extending orthogonally to the first grating supporting element 46 and perpendicular to the grating side elements 38. The elongated fasteners 44 can be configured to mate with the fastening holes 24 of the sieve element. The sieve element 16 can be attached to the lattice element 14 by mating the elongated fastening elements 44 with the fastening holes 24 of the sieve element. Part of the elongated attachment 44 may extend slightly above the screening surface of the screen element when the screen element 16 is attached to the end grate element 14. The openings 24 of the attachment of the screen element may contain a conical channel, so that part of the elongated attachments 44 passing over the screening surface of the screen element, can be melted and fills the conical channel. Alternatively, the sieve element mounting holes 24 may be made without a conical channel and a portion of the elongated mounts extending over the screening surface of the screen element 16 may be configured to form a bead on the screening surface upon melting. See fig. 34 and 35. Once attached, the screen element 16 will enclose at least one grate opening 50. Materials passing through screen holes 86 will pass through screen hole 50. The arrangement of the elongated attachment elements 44 and the corresponding arrangement of the screen element attachment holes 24 provide a guide for attaching the screen elements 16 to the screen elements, facilitating assembly of the screen elements. The elongated attachment members 44 extend through the screen element attachment holes 24, guiding the screen element to the proper location on the surface of the screen element. The fastening by means of the elongated fastening elements 44 and the mesh element fastening holes 24 additionally ensures secure attachment to the grating element and strengthens the screening surface of the sieve 10 assembly.

In FIG. 4 shows the central grill element 18. As shown in FIG. 1 and FIG. 1A, the central grate 18 may be included in the screen assembly. The central grating element 18 has latches 42 and latch holes 40 on both end elements 36 of the grating element. The end grating element 14 has latches 42 and latch holes 40 on only one of the two end elements 36 of the grating element. The central grid elements 18 can be attached to the remaining grid elements at each of their end grid elements and side grid elements.

In FIG. 5 shows a plan view of the connecting strip 12. FIG. 5A shows a bottom view of the bonding strip 12. The bonding strips 12 include latches 42 and latch holes 40 so that the bonding strip 12 can be snapped onto the assembly side of the screen panels (see FIG. 9). As with the gratings, the fasteners on the connecting strip 12 are shown as latches and latch holes, but other fasteners may be used to engage the grating fasteners. Handles may be attached to connecting strips 12 (see, for example, FIG. 7) which may facilitate transport and installation of the screen assembly. Labels and/or tags may also be attached to the connecting strips. As discussed above, the bonding strips 12 can increase the stability of the grid frame and can distribute the compression loads of the vibrating screener when the screen assembly is under compression forces, as shown in US Patent No. 7,578,394 and US Patent Application No. 12/460,200.

Screen elements, screen assemblies, and parts thereof, including connectors/attachments as described herein, may contain nanomaterial distributed therein for increased 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 distributed in sieve elements and sieve assemblies and their parts in various percentages depending on the required properties of the final product. For example, specific percentages may be included to increase the strength of the element or to make the screening surface wear resistant. The use of a material made from an injection molded thermoplastic having nanomaterials dispersed therein may provide increased strength while using less material. Thus, the structural elements, including the screen element frame supports and the screen element support elements, can be made smaller and stronger and/or lighter. This is particularly advantageous in the manufacture of relatively small individual components that fit into a complete sieve assembly. Also, instead of manufacturing separate grating elements that are fastened together by latches, one large grating structure can be made having nanomaterials dispersed therein, which is relatively light and strong. The individual screen elements, with or without nanomaterials, can then be attached to one completed grid frame structure. The use of nanomaterials in the screen element will provide increased strength while reducing the weight and size of the element. This can be particularly useful when injection molding screen elements having extremely small openings, since the openings are supported by the surrounding materials/elements. Another benefit of incorporating nanomaterials into screen elements is an improved screening surface that is durable and wear resistant. Screen surfaces are prone to wear due to heavy use and exposure to abrasive materials, and the use of a thermoplastic and/or thermoplastic having abrasion resistant nanomaterials provides a screen surface with a long service life.

- 22 042381

In FIG. 6 shows part 15 of an assembly of a number of grid element blocks. In FIG. 6A is an exploded view of a portion of the assembly shown in FIG. 6, which shows the individual grid elements and the direction of their attachment to each other. Part of the Assembly contains two blocks 14 of the end lattice element and three blocks 18 of the Central lattice element. The end grille blocks 14 form the ends of the assembly part, while the central grille blocks 18 are used to join the two end grille blocks 14 through connections between the latches 42 and the latch holes 40. The lattice element blocks shown in FIG. 6 are shown with sieve elements 16 attached. By fabricating the screen assembly from the screen elements into the assembly portion, each screen element can be created according to the selected specification and the screen assembly can be created from a plurality of screen elements in the configuration required for screening applications. The screen assembly can be quickly and easily assembled and will have accurate screening capabilities and substantial stability under load pressure. Due to the design configuration of the screen frame and the screen members 16, the configuration of the plurality of individual screen members forming the screening surface of the screen assembly 10, and the fact that the screen members 16 are injection molded from thermoplastic, the openings in the screen members 16 are relatively stable and retain their hole sizes for optimal screening under various loading conditions, including compressive loads, and concave bends and tension.

In FIG. 7 shows a sieve 10 assembled with connecting strips 12 having handles attached to the connecting strips 12. The assembled sieve consists of a plurality of grating blocks attached to each other. The screen element blocks have screen elements 16 attached to their top surfaces. In FIG. 7A is a cross-sectional view of the portion A-A shown in FIG. 7 showing the individual screen elements attached to the screen elements forming the screening surface. As shown in FIG. 7A, the screen members may have screen support members 48 configured such that the screen assembly has a slightly concave shape if the screen support members 48 are secured to each other by means of latches 42 and latch holes 40. Because the screen assembly is designed with a slightly concave shape, it can be configured to deform to a desired concavity when a compression load is applied without the need to guide the screen assembly into a concave shape. Alternatively, the screen elements may be configured to provide a slightly convex screen assembly or a substantially flat screen assembly.

In FIG. 8 shows an isometric plan view of an assembly of screens partially covered by screen elements 16 . This figure shows the end screen blocks 14 and the central screen blocks 18 fastened together to form a screen assembly. The screening surface can be completed by attaching the screen elements 16 to the uncovered grid element blocks shown in the figure. The sieve elements 16 may be attached to the individual grid elements before the grid frame is formed, or attached to the grid elements after the grid elements have been fastened together to form the grid frame.

In FIG. 9 is an exploded isometric view of the sieve assembly shown in FIG. 1. This figure shows eleven parts of the assembly fastened to each other by means of latches and latch holes along the end elements of the lattice element of the lattice element blocks in each part of the assembly. Each part of the Assembly has two blocks 14 of the end lattice element and three blocks 18 of the Central lattice element. The connecting strips 12 are snap-fitted on each side of the assembly. Screen assemblies of various sizes can be created using a different number of assembly parts or a different number of central grid element blocks in each assembly part. The assembled sieve assembly has a continuous screening surface of the sieve assembly, consisting of a plurality of screening surfaces of the sieve element.

In FIG. 10 and 10A illustrate the attachment of screen elements 16 to end screen assembly 14 in accordance with an exemplary embodiment of the present invention. The screen elements 16 can be aligned with the end screen element block 14 by means of the elongated attachment elements 44 and the screen element attachment holes 24, so that the elongated attachment elements 44 pass through the screen element attachment holes 24 and extend slightly beyond the screening surface of the screen element. The elongated attachment members 44 can be melted to fill the conical channels of the screen element attachment holes 24 or alternatively to form ridges on the screening surface of the screen element, attaching the screen element 16 to the screen element block 14 . Fastening by means of elongated fastening members 44 and sieve element fastening holes 24 is only one embodiment of the present invention. Alternatively, the screen element 16 may be attached to the end screen element block 14 by means of a binder, fasteners and fastener holes, laser welding, etc. Although shown to have two screen elements for each screen element, the present invention includes alternative configurations of one screen element per screen element, multiple screen elements per screen element, one screen element per screen opening, or having one a sieve element covering a plurality of lattice elements. The end grille 14 may be substantially rigid and may be formed as one piece made from injection molded thermoplastic.

In FIG. 10B is a plan view of the end grate assembly shown in FIG. 10A with screen elements 16 attached to the end screen. In FIG. 10C is an enlarged cross-sectional view of the B-B portion of the end grill block shown in FIG. 10V. The sieve element 16 is located on the end screen element block so that the elongated attachment element 44 extends through the attachment opening and beyond the screening surface of the sieve element. The portion of the elongated attachment member 44 extending through the attachment hole and beyond the screening surface of the screen element may be melted to attach the screen element 16 to the end screen element assembly as described above.

In FIG. 11 and 11A illustrate the attachment of the screen elements 16 to the central screen unit 18 in accordance with an exemplary embodiment of the present invention. The screen elements 16 can be aligned with the central grating element block 18 by means of the elongated attachment elements 44 and the screen element attachment holes 24, so that the elongated attachment elements 44 pass through the screen element attachment holes 24 and extend slightly beyond the screening surface of the screen element. The elongated attachment members 44 may be melted to fill the conical channels of the screen element attachment holes 24 or alternatively to form ridges on the screening surface of the screen element by attaching the screen element 16 to the central grate assembly 18 . Fastening by means of elongated fastening elements 44 and fastening holes 24 of the sieve element is only one embodiment of the present invention. Alternatively, the screen element 16 may be attached to the end screen element block 14 by means of a binder, fasteners and fastener holes, etc. Although shown to have two screen elements for each screen element, the present invention includes alternative configurations of one screen element per screen element, one screen element per screen opening, multiple screen elements per screen element, or having one screen element covering a plurality of lattice element blocks. The central grille unit 18 may be substantially rigid and may be a single piece made from an injection molded thermoplastic.

In FIG. 12 and 12A show screens 10 assembled on a vibratory screening machine having two screening surfaces. The vibrating screening machine may have compression assemblies on the side members of the vibrating screening machine as shown in US Pat. No. 7,578,394. A compression force may be applied to the bonding strip or side member of the screen assembly so that the screen assembly flexes downward into a concave shape. The underside of the sieve assembly can mate with the mating surface of the sieve assembly of the vibrating screening machine as shown in US Pat. No. 7,578,394 and US Patent Application No. 12/460,200. The vibrating screening machine may include a central wall element configured to receive a side screen assembly connecting strip opposite the side screen assembly being compressed. The center wall member may be angled so that a compressive force applied to the screen assembly bends the screen assembly downward. The screen assembly may be installed in the vibratory screening machine so that it is configured to receive the material to be screened. The screen assembly may include guide recesses configured to mate with the guides of the vibrating screen machine so that the screen assembly can be guided into place during installation and may include guide assembly configurations as shown in US Patent Application No. 12/460,200 .

In FIG. 12B is a front view of the vibrating screening machine shown in FIG. 12. In FIG. 12B shows screen assemblies 10 mounted on a vibrating screening machine with compression applied to deflect the screen assemblies downward into a concave shape. Alternatively, the screen assembly may be formed into a predetermined concave shape without the application of a compression force.

In FIG. 13 and 13A show the installation of a screen assembly 10 in a vibratory screening machine having a single screening surface. The vibrating screening machine may have a compression assembly on the side member of the vibrating screening machine. The screen assembly 10 may be positioned in the vibratory screening machine as shown. A compression force may be applied to the bonding strip or side member of the screen assembly so that the screen assembly flexes downward into a concave shape. The underside of the sieve assembly can mate with the mating surface of the sieve assembly of the vibrating screening machine as shown in US Patent No. 7,578,394 and US Patent Application No. 12/460,200. The vibratory screening machine may include a side member wall opposite a compression assembly configured to receive a connecting strip or screen side member assembly. The wall of the side member may be angled so that a compressive force applied to the screen assembly bends the screen assembly downward. The sieve assembly may be installed in the vibrating screening machine so that it is configured to receive the material to be screened. The sieve assembly may contain guide recesses made with

- 24 042381 the possibility of docking with the guides of the vibrating screening machine, so that the sieve assembly can be guided into place during installation.

In FIG. 14 shows a front view of screen assemblies 52 mounted on a vibratory screen machine having two screen surfaces, in accordance with an exemplary embodiment of the present invention. The sieve assembly 52 is an alternative embodiment in which the sieve assembly has been configured to be inserted into a vibrating sifter without applying a load to the sieve assembly, i.e. the sieve assembly 52 includes a bottom portion 52A which is formed such that it mates with the base 83 of the vibrating sieving machine. The lower part 52A may be formed together with the screen assembly 52 or may be a separate part. The screen assembly 52 contains similar components to the screen assembly 10 containing the screen members and screen elements, but also includes a bottom portion 52A that allows it to be placed on the base 83 without being compressed into 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 place by applying a compressive force to the side member of the screen assembly 52. The bottom of the sieve assembly 52 can be configured to mate with any type of oscillating sieving machine docking surface.

In FIG. 15 is a front view of a screen assembly 53 mounted on a single screen vibrating screen machine according to an exemplary embodiment of the present invention. The screen assembly 53 has similar components to the screen assembly 52 described above, including a bottom portion 53A that is formed such that it mates with the base 87 of the vibrating screener.

In FIG. 16 shows part of the end support frame assembly, and FIG. 16A is an exploded view of a portion of the end support frame assembly shown in FIG. 16. Part of the end support frame assembly shown in FIG. 16 contains eleven blocks 14 of the end grille. Alternative configurations may be used having more or fewer end grid element blocks. Blocks 14 of the end grill element are fastened to each other by means of latches 42 and holes 40 of the latches along the side elements of the blocks 14 of the end grill element. In FIG. 16A shows the fastening of the individual blocks of the end grate so that part of the end support frame assembly is created. As shown, a portion of the end support frame assembly is covered with screen elements 16 . Alternatively, part of the end support frame assembly may be formed from end screens prior to attaching the screen elements, or partly from pre-coated screen blocks and partly from uncoated screen blocks.

In FIG. 17 shows the assembled central support frame, and FIG. 17A is an exploded view of a portion of the center support frame assembly shown in FIG. 17. The center support frame assembly shown in FIG. 17 contains eleven blocks 18 of the central lattice element. Alternative configurations may be used having more or fewer central grid element blocks. Blocks 18 of the central lattice element are fastened to each other by means of latches 42 and holes 40 of the latches along the side elements of the blocks 18 of the central lattice element. In FIG. 17A shows the fastening of individual blocks of the central lattice element, so that a part of the assembly of the central support frame is created. As shown, a portion of the central support frame assembly is covered with screen members 16 . Alternatively, a portion of the central support frame assembly may be formed from the center grid members prior to attaching the screen elements, or partly from pre-coated grid units and partly from uncoated grid units.

In FIG. 18 is an exploded view of a screen assembly having three center support frame assembly parts and two end support frame assembly parts. The support frame assemblies are fastened to each other by means of latches 42 and latches holes 40 on the end elements of the lattice element. Each block of the central lattice element is attached to two other blocks of the lattice element by means of end elements. The end elements 36 of the end screen blocks, which do not have latches 42 or openings 40 of the latches, form the end edges of the sieve assembly. The screen assembly can be made with more or less central support frame assembly parts or more or less frame assembly parts. Connecting strips can be added to the side edges of the screen assembly. As shown, the screen assembly has the screen elements installed on the screen element blocks prior to assembly. Alternatively, the sieve elements 16 may be installed after complete or partial assembly.

In FIG. 19 illustrates an alternative embodiment of the present invention in which the screen 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 54 screen assembly can be used with a flat screening surface. See fig. 39. As shown, the screen assembly 54 has connecting strips 12 attached to the sides of the screen assembly 54. Screen 54 assembly can be made with various designs

- 25 042381 grids and sieve elements described in this document.

In FIG. 20 illustrates an alternative embodiment of the present invention in which the screen 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 screen assembly 56 has connecting strips 12 attached to the sides of the screen assembly. The screen assembly 56 may be configured with various embodiments of the screen designs and screen elements described herein.

In alternative embodiments of the present invention, a screen assembly 410 is provided having screen elements 416, central screen blocks 418, and end screen blocks 414. See, for example, FIG. 47. The screen element 416 may be made from an injection molded thermoplastic and may contain all of the components of the screen element 16 provided above. The sieve element 416 may be included in any of the sieve assemblies disclosed herein (eg, 10 and 52-54) and is interchangeable with the sieve element 16. The screen element 416 may include centering holes 424 that may be located in the center of the screen element 416 and at each of the four corners of the screen element 416 . See, for example, FIG. 48 and 48A. More or fewer centering holes 424 may be provided on screen element 416, and many configurations may be provided. The centering holes 424 may be substantially the same as the mounting holes 24 and may be used to center the screen element 416 on the grate. Alternatively, the screen element 416 may be centered without centering holes 424. The screen element 416 may include a plurality of tapered return channels 470 that may facilitate removal of the screen element 416 from the mold, and the mold may have injection pins configured to eject the screen element from the form. See, for example, FIG. 48 and 48A.

On the underside of screen element 416, a first engagement arrangement may be provided, which may be a plurality of extensions, cavities, or a combination of extensions and cavities. The first engagement arrangement of screen element 416 may be configured to dock with a complementary second engagement arrangement on the top surface of the screen element assembly. For example, in FIG. A plurality of cavities 472 are provided at 48B and 48C. A plurality of cavities 472 may be located along the end portions 20 and side portions 22 between the centering holes 424. Additional cavities 272 may be located along all or part of the first screen element support 28 and along all or part of the second support element 30 for the sieve element. Although shown as elongated cavities, cavities 472 may be of various configurations, sizes, and depths. Moreover, the first engagement arrangement on the screen element 416 may be extensions instead of cavities. The first engagement arrangement of the screen element 416 may be configured to be mated with a complementary second engagement arrangement on the screen assembly such that a portion of the screen element 416 overlaps at least a portion of the screen assembly, whether or not the screen element 416 has a screen assembly or a screen assembly. extensions or cavities.

An end screen assembly 414 and a central screen assembly 418 may be included in the screen 410 assembly. See, for example, FIG. 49, 49A, 50 and 50A. The end grille assembly 414 and central grille assembly 418 may be injection-molded thermoplastic and may comprise all of the components of the end grille assembly 14 and central grille assembly 18 discussed above. End grille block 414 and central grille block 418 can be used interchangeably in all cases where end grille block 14 and central grille block 18 are designated. The end grille unit 414 and the central grille unit 418 may have a plurality of elongated centering members 444 that may be substantially the same as the attachment members 44 . The arrangement of the centering members 444 may correspond to the centering holes 424 of the screen members 416 such that the screen members 416 may be centered on the end screen block 414 and the center screen block 418 for attachment.

The end screen block 414 and the central screen block 418 may comprise a second engagement arrangement on the top surface of both the end screen block 414 and the central screen element block 418, wherein the second engagement arrangement may be complementary to the first engagement arrangement of the sieve element 416, so that the screen element can be docked to the screen element assembly by docking the first and second clutch arrangements. In one embodiment of the present invention, the second clutch arrangement may be a plurality of alloy strips 476 located along the upper surface of the side elements 38 of the lattice element and the end elements 36 of the lattice element. The end grille block 414 and the central grille block 418 may also comprise a plurality of fused strips 478, which may be short fused strips having a height less than the height of the fused strips 476 along the upper surface.

- 26 042381 the first support element 46 of the lattice element and the second support element 48 of the lattice element. See, for example, FIG. 49-50A. Although shown as elongated extensions, the alloy strips 476 (and 478) can be of various shapes and sizes and can be arranged in various configurations. Alternatively, the second engagement arrangement may be cavities or the like and may be configured to receive extensions emanating from the screen element. The second clutch arrangement may include both extensions and cavities.

Each of the plurality of cavities 472 is configured to receive alloy strips 476 and short alloy strips 478 located on the lattice elements (414, 418, 458 and 460). See, for example, FIG. 45A-45E and 46. As shown in FIG. 45B-45E, the fused strips 476 fit within the plurality of cavities 472 during placement of the screen element 416 on the grate. The voids 472 may have a width C that is slightly greater than the width D of the alloy strip 476. The cavity 472 may have a depth A that is slightly less than the height B of the alloy strip 476. See, for example, FIG. 47. Height B of alloy strip 476 may be approximately 0.056 inches. Prior to melting the alloyed strips 476, the screen element 416 may rest on the alloyed strips 476 without coming into contact with the rest of the screen element. The sieve element 416 and the grid elements can be joined together by laser welding. The connection can be made by forming a chemical bond between the cavities 472 and the alloy strips (476 or 478) or by melting parts of the materials of each component so that the components solidify together. In one embodiment, by centering the screen element 416 on the grating, the fusion strip 476 (or shortened fusion strip 478) can be melted, whereby the melted portion of the fusion strip 476 fills all or part of the width C of cavity 472. In some embodiments, approximately 0.006 inch of fusion strip strip 476 may be melted, whereby all or part of the width of cavity 472 may be filled. Melting of alloy strip 476 may be performed by laser welding, which may attach screen element 416 to the grate. Laser 500 may be configured and controlled to achieve a specific depth of alloy strip 476.

Fused strips 476 (or shortened fused strips 478) may contain carbon, graphite, or other materials configured to respond to a particular laser wavelength. The fusion strips can additionally be made to match the laser to be used for laser welding. The fusion strips may be of specific length to suit the laser 500. Although shown as elongated protrusions, other shapes and/or designs may be provided for the fusion strips in accordance with the requirements of the selected laser. In embodiments having alloy stripes on the screen elements, the screen elements 416 generally do not contain carbon or graphite. The sieve element 416 and fusion strips can be made from a variety of materials such that the selected laser 500 can pass through the sieve element 416 without melting the sieve element 416 and contact the fusion strips. See, for example, FIG. 45B and C. Screen element 416 may be made of TPU or a similar material having the performance properties required for screening applications. The sieve element 416 may be substantially clean. The lattice elements (414 and 418) may be made of nylon or similar materials. The alloyed strips may have a higher melting point than the material of the screen element 416, so that melting the alloyed strips also melts part of the screen element 416, which can be done by transferring heat from the melted portion of the alloyed strip 476 that is in contact with the screen element 416 in the cavity. 472. Thus, the screen element 416 is welded to the screen element. See, for example, FIG. 51, 51A, 52 and 52A.

Laser welding is generally performed by focusing a laser beam in the direction of a seam or area to change the material from a solid state to a liquid state, and upon removal of the laser beam, the material returns to a solid state. Laser welding is a type of fusion welding and can be done by conduction or penetration. Welding by conduction 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 lattice element having alloy strips involves laser welding of two different materials together. As a rule, this cannot be done by laser welding; however, application of the laser 500 through the screen element 416 to the fusion strips, which have conductive properties to generate heat when the selected laser 500 is applied, causes the fusion strips (476 or 478) to melt. Similarly, the heat generated by the conduction and/or the molten material of the alloy strip causes a portion of the screen element to melt. The two liquid materials combine and create a strong solid bond between the screen element and screen element when the laser is removed and the combined materials return to a solid state. Through the formation of laser welded joints between the screen element and the grid elements, the fastening between the components becomes very strong, which is essential for screen assembly components used in vibrating screening machines. Screen assemblies may be subject to vibration

- 27 042381 forces over 8 g, abrasives and chemicals, and high load requirements. Therefore, the screen assemblies must be very strong and resistant. Embodiments of the present invention provide screen assemblies made from a plurality of pieces fastened together. The fabrication of screen assemblies from smaller additional parts enables injection molding of screen elements with very small openings, for example, having a thickness of from about 43 microns to about 100 microns. The strength of the laser welding adds to the overall strength of the screen assemblies, providing the benefits of micro-injection molding of the screen elements while maintaining the durability of the screen assemblies. Laser welding also provides a more efficient fastening procedure than other fastening procedures such as thermal fusion. In some embodiments, laser welding can be completed in about 8-10 seconds, while thermal fusion can take about 1.5 minutes in other embodiments.

The end grille block 414 (or 14) and the central grille block 418 (or 18) may comprise a secondary support frame 488 enclosing the grille openings 50. The secondary support frame 488 may enclose all or only a portion of the grate opening 50. The secondary support frame 488 improves the strength and durability of the end grille block 414 (or 14) and the central grille block 418 (or 18). The secondary support frame 488 adds to the overall strength of the 410 screen assembly, allowing it to withstand vibrational forces in excess of 8 g.

In FIG. 21 and 21A show an alternative embodiment of the present invention incorporating pyramid-shaped lattice element blocks. The screen assembly is shown with connecting strips 12 attached. The screen assembly comprises central and end grid units 14 and 18 (or 414 and 418) and pyramidal-shaped central and end grid units 58 and 60 (or 458 and 460). By incorporating the pyramid-shaped screen element blocks 58 and 60 into the screen assembly, an improved screening surface can be obtained. In addition, the material to be screened can be controlled and guided. The screen assembly can be concave, convex or flat. The screen assembly may be flexible and may be deformed into a concave or convex shape when a compressive force is applied. The screen assembly may include guide recesses that can mate with guide mating surfaces on the vibratory screening machine. Different configurations of screen blocks and pyramidal screen blocks can be used, which can increase or decrease screening surface area and material flow characteristics. Unlike mesh screens or the like, which may include corrugations or other operations to increase surface area, the screen assembly shown is supported by a screen frame that can be substantially rigid and withstand substantial loads without damage or failure. Under high material flows, traditional sieve assemblies with serrated screening surfaces are often flattened or damaged due to the weight of the material, thus affecting efficiency and reducing the screening surface area of the sieve assemblies. The screen assemblies disclosed herein are difficult to damage due to the strength of the screen frame, and the benefits of the increased surface area provided by the inclusion of pyramid-shaped screen elements can be maintained under substantial loads.

The end lattice element 58 of pyramidal shape is illustrated in FIG. 22 and FIG. 22A. The end lattice element 58 of pyramidal shape contains the first and second frames of the lattice, forming the first and second openings 74 of the lattice of the inclined surface. The end lattice element 58 of a pyramidal shape includes a ribbed portion 66, side elements/base elements of the lattice element 64 and first and second corner surfaces 70 and 72, respectively, which peak at the ribbed portion 66 and extend down to the side element 64. Lattice elements 58 and 60 pyramid-shaped have triangular end elements 62 and triangular middle support elements 76. The angles shown for the first and second corner surfaces 70 and 72 are given by way of example only. Different angles can be used to increase or decrease the surface area of the screening surface. The pyramid-shaped end grille 58 has fasteners along the side members 64 and at least one triangular end member 62. The fasteners may be latches 42 and latch holes 40 so that a plurality of lattice element blocks 58 can be fastened together. Alternatively, latches 42 and latch holes 40 may be used to attach the pyramidal end grid 58 to the end grid 14, central grid 18, or central pyramid 60. The elongated fasteners 44 may be provided on the first and second inclined surfaces 70 and 72 so that they mate with the fastening holes 24 of the screen element. The element 16 of the sieve can be attached to the end lattice element 58 of the pyramidal shape by joining the elongated elements 44 of the attachment with the holes 24 of the attachment of the sieve element. Part of the elongated fastening element 44 may extend slightly above the screening surface of the sieve element when the sieve element 16 is attached to the end lattice element 58 of a pyramidal shape. The openings 24 of the sieve element attachment may comprise a conical channel so that part of the elongated attachment elements 44

- 28 042381 the sieve element above the screening surface can be melted and fills the conical channel. Alternatively, the sieve element mounting holes 24 may be made without a conical channel and a portion of the elongated mounts extending over the screening surface of the screen element 16 may be melted to form a bead on the screening surface. Once attached, the screen element 16 may surround the first 74 and second openings of the inclined grid. Materials passing through screen holes 86 will pass through the first 74 and second screen holes.

The pyramid-shaped central lattice element 60 is illustrated in FIG. 23 and FIG. 23A. The pyramid-shaped central lattice element 60 includes first and second lattice frames forming the first and second openings 74 of the inclined surface lattice. The central lattice element 60 of a pyramidal shape includes a ribbed portion 66, the side elements/base elements of the lattice element 64 and the first and second corner surfaces 70 and 72, which peak in the ribbed portion 66 and extend down to the side element 64. The central lattice element 60 of the pyramidal shape has triangular end members 62 and triangular middle members 76. The angles shown for the first and second corner surfaces 70 and 72 are by way of example only. Different angles can be used to increase or decrease the surface area of the screening surface. The central pyramidal lattice element 60 has fasteners along the side elements 64 and both triangular end elements 62. The fasteners may be latches 42 and latch holes 40 so that a plurality of central pyramidal lattice elements 60 can be fastened together. Alternatively, the latches 42 and latch holes 40 may be used to secure the central pyramid-shaped lattice member 60 to the end lattice element 14, the central lattice element 18, or the pyramid-shaped end lattice element 58. The elongated fasteners 44 may be provided on the first and second inclined surfaces 70 and 72 so that they mate with the fastening holes 24 of the screen element. The element 16 of the sieve can be attached to the central lattice element 60 of the pyramidal shape by joining the elongated elements 44 of the attachment with the holes 24 of the attachment of the sieve element. Part of the elongated fastening element 44 may extend slightly above the screening surface of the sieve element when the sieve element 16 is attached to the central lattice element 60 of a pyramidal shape. The sieve element attachment holes 24 may comprise a conical channel so that a portion of the elongated attachment elements 44 extending over the screening surface of the sieve element can be melted and fill the conical channel. Alternatively, the holes 24 of the sieve element can be made without a conical channel and part of the elongated elements of the mount, passing over the screening surface of the screen element 16, can be melted to form a bead on the screening surface. Once attached, the sieve element 16 will surround the opening 74 of the slanted grate. Materials passing through screen holes 86 will pass through screen hole 74. While pyramidal and planar shaped screen designs are shown, it should be understood that various shaped screen elements and corresponding screen elements can be manufactured in accordance with the present invention.

In FIG. 24 shows part of an assembly of a series of blocks of a pyramid-shaped lattice element. In FIG. 24A is an exploded view of a portion of the assembly shown in FIG. 24, which shows individual pyramid-shaped lattice elements and the mounting direction. The assembly part contains two end lattice elements 58 of a pyramidal shape and three central lattice elements 60 of a pyramidal shape. The pyramidal end grids 58 form the ends of the assembly portion, while the pyramidal center grids 60 are used to join the two end grids 58 through connections between the latches 42 and the latch holes 40. The pyramidal lattice elements shown in Figs. 24 are shown with sieve elements 16 attached. Alternatively, part of the assembly may be formed from the screen elements prior to attaching the screen elements, or partly from pre-coated pyramid-shaped lattice blocks and partly from uncoated pyramid-shaped lattice blocks.

In FIG. 24B and 24C illustrate the attachment of screen elements 16 to a pyramid-shaped end screen 58 in accordance with an exemplary embodiment of the present invention. The screen elements 16 can be aligned with the pyramid-shaped end grid element 58 by means of the elongated attachment elements 44 and the screen element attachment holes 24, so that the elongated attachment elements 44 pass through the screen element attachment holes 24 and may extend slightly beyond the screening surface of the screen element. Part of the elongated fastening elements 44 extending beyond the screening surface of the sieve element can be melted to fill the conical channels of the holes 24 of the fastening of the sieve element or, alternatively, to form rollers on the screening surface of the sieve element, attaching the sieve element 16 to the lattice element 58 pyramidal forms. Fastening by means of elongated fastening elements 44 and fastening holes 24 of the sieve element is

- 29 042381 is only one embodiment of the present invention. Alternatively, the screen element 16 may be attached to the pyramid-shaped end screen element 58 by means of a binder, fasteners and fastener holes, etc. While it is shown that there are four screen elements for each pyramidal end screen 58, the present invention includes alternative configurations of two screen elements per pyramid end screen 58, multiple screen elements per pyramid end screen 58, or having a single screen element. a sieve covering an inclined surface of a plurality of blocks of a pyramid-shaped lattice element. The pyramid-shaped end grille 58 may be substantially rigid and may be a single piece made from an injection molded thermoplastic.

In FIG. 24D and 24E illustrate the attachment of sieve elements 16 to a pyramidal-shaped central lattice element 60 in accordance with an exemplary embodiment of the present invention. The screen elements 16 can be aligned with the central pyramid-shaped grating element 60 by means of the elongated attachment elements 44 and the screen element attachment holes 24, so that the elongated attachment elements 44 can pass through the screen element attachment holes 24 and can extend slightly beyond the screening surface of the screen element. Part of the elongated fasteners 44 extending beyond the screening surface of the sieve element can be melted to fill the conical channels of the holes 24 of the fastening of the sieve element or, alternatively, to form rollers on the screening surface of the sieve element, attaching the sieve element 16 to the block 60 of the lattice element pyramidal shape. Fastening by means of elongated fastening elements 44 and fastening holes 24 of the sieve element is only one embodiment of the present invention. Alternatively, the sieve element 16 may be attached to the pyramid-shaped central lattice element 60 by means of a binder, fasteners and fastener holes, etc. While it is shown that there are four sieve elements for each central pyramidal lattice element 60, the present invention includes alternative configurations of two sieve elements per pyramidal shaped central lattice element 60, multiple sieve elements per pyramidal shaped central lattice element 60, or having one a sieve element covering an inclined surface of a plurality of pyramid-shaped lattice elements. The pyramid-shaped central lattice element 60 may be substantially rigid and may be a single piece made from an injection molded thermoplastic. While pyramidal and planar shaped screen designs are shown, it should be understood that various shaped screen elements and corresponding screen elements can be manufactured in accordance with the present invention.

In FIG. 53-56A show pyramidal end and center lattice members 458 and 460, respectively, in accordance with exemplary embodiments of the present invention. The end and center pyramidal grills 458 and 460 may be injection molded from thermoplastic and may have all of the components of the pyramidal end and center lattices 58 and 60 discussed herein above. As with the end screen assembly 414 and the center screen assembly 418, the pyramidal end and center screens 458 and 460 may have centering elements 444 corresponding to the centering holes 424 of the screen element 416 so that the screen elements 416 can be centered on end and central lattice elements 458 and 460 of a pyramidal shape for fastening. The pyramid-shaped end and center grid members 458 and 460 may have second engagement arrangements, such as a plurality of alloy strips 476 and short alloy strips 478. many cavities. The sieve elements 416 may be laser welded to the pyramidal lattice elements. The end and center lattice elements 458 and 460 of the pyramidal shape may include a secondary support frame 488 covering the openings 74 of the lattice. The secondary support frame 488 may enclose all or only a portion of the grate opening 74. The secondary support frame 488 enhances the strength and durability of the end and center lattice members 458 and 460 of the pyramidal shape. The pyramidal end and center lattice elements 458 and 460 may include a flattened ribbed portion 465 and may have retainer centralizers 490 on rib 66. See, for example, FIG. 53. The flattened ribbed portion 465 may allow for easier molding than rounded or pointed embodiments and may allow easier release and/or removal of the lattice elements from molds. Embodiments may include one or more retainer centralizers 490 that may be used for alignment and/or assembly during laser welding. The retainers can engage the gratings in the retainer centralizers 490 to align the laser weld. The flattened ribbed portion 465 may provide easier engagement of the retainer centralizers 490.

In FIG. 25 shows a plan view of an 80 screen assembly having pyramidal lattice elements.

- 30 042381 shapes, which can be any of the lattice elements 14, 18, 414 and 418. As shown, the sieve 80 assembly is formed from parts of the sieve assembly fastened to each other, which vary from flat parts of the assembly to parts of the pyramid-shaped assembly . Alternatively, the parts of the pyramid-shaped assembly may be fastened to each other, or fewer or more parts of the pyramid-shaped assembly may be used. In FIG. 25A is a cross-sectional view of the C-C portion of the screen assembly shown in FIG. 25. As shown, the screen assembly has five rows of pyramidal screen blocks and six rows of flat screens, with rows of flat screen blocks between each row of pyramidal screen. The connecting strips 12 are attached to the screen assembly. Any combination of flat grid rows and pyramid shaped grid rows may be used. In FIG. 25B is an enlarged cross-sectional view of FIG. 25A. In FIG. 25B shows the attachment of each grid element to another grid element and/or connection strip 12 by means of snaps and snap holes.

In FIG. 26 is an exploded isometric view of an assembly of screens having pyramid-shaped lattice element blocks. This figure shows eleven parts of the assembly fastened to each other by means of latches and latch holes along the side elements of the lattice element of the lattice element blocks in each part of the assembly. Each flat part of the assembly has two end grids (14 or 414) and three central grids (18 or 418). Each part of the pyramid-shaped assembly has two end pyramid-shaped lattice elements (58 or 458) and three central pyramid-shaped lattice elements (60 or 460). Connecting strips 12 are attached at each end of the assembly. Screen assemblies of different sizes can be created using different numbers of assembly parts or different numbers of central grate blocks. The screening surface area can be increased by including more pyramid-shaped assembly parts or reduced by including more flat assembly parts. The assembled sieve assembly has a continuous screening surface of the sieve assembly, consisting of a plurality of screening surfaces of the sieve element.

In FIG. 27 shows the installation of sieves 80 as an assembly on a vibratory screening machine having two screening surfaces. In FIG. 30 is a front view of the vibrating machine shown in FIG. 27. The vibrating screening machine may have compression assemblies on the side members of the vibrating screening machine. The screen assemblies may be arranged in the vibratory screening machine as shown. A compression force may be applied to the side member of the screen assembly so that the screen assembly flexes downward into a concave shape. The underside of the sieve assembly can mate with the mating surface of the sieve assembly of the vibrating screening machine as shown in US Patent No. 7,578,394 and US Patent Application No. 12/460,200. The vibrating screening machine may include a central wall element configured to receive a side screen assembly opposite the side screen assembly being compressed. The center wall element may be angled so that a compressive force applied to the screen assembly bends the screen assembly downward. The sieve assembly may be installed in the vibrating screening machine so that it is configured to receive the material to be screened. The screen assembly may include guide recesses configured to mate with the guides of the vibrating screening machine so that the screen assembly can be guided into place during installation.

In FIG. 28 is an isometric view of a screen assembly having pyramid-shaped lattice elements, with the screen elements not attached. The screen assembly shown in Fig. 28 is slightly concave, however, the screen assembly may be more concave, convex or flat. The screen assembly may be made of a plurality of assembly parts, which may be any combination of flat assembly parts and pyramid-shaped assembly parts. As shown, eleven assembly parts are included, however, more or fewer assembly parts may be included. The sieve assembly is shown without elements of 16 (or 416) sieves. The screen elements can be assembled together before or after the screen elements are attached to the screen elements, or any combination of screen elements having attached screen elements and screen elements without screen elements can be fastened together. In FIG. 29 shows the screen assembly shown in FIG. 28 partially covered with sieve elements. The pyramid-shaped assembly parts comprise pyramid-shaped end grids 58 (or 458) and pyramid-shaped central grids 60 (or 460). The flat portions of the assembly comprise flat end grids 14 (or 414) and flat central grids 18 (or 418). The grid element blocks can be fastened to each other by means of latches and latching holes.

In FIG. 31 shows the installation of a screen assembly 81 in a vibrating screening machine having one screening surface according to an exemplary embodiment of the present invention. The 81 sieve assembly has a similar configuration to the 80 sieve assembly, but contains additional pyramidal and flat assemblies. vibratory screening machine mo

- 31 042381 may have a compression assembly on the side member of the vibrating screening machine. The screen assembly 81 may be positioned in the vibrating screening machine as shown. A compression force may be applied to the side member of the screen assembly 81 so that the screen assembly 81 flexes downward into a concave shape. The underside of the sieve assembly can mate with the mating surface of the sieve assembly of the vibrating screening machine as shown in US Patent No. 7,578,394 and US Patent Application No. 12/460,200. The vibrating screening machine may include a side member wall opposite a compression assembly configured to receive the side screen member assembly. The wall of the side member may be angled so that a compressive force applied to the screen assembly bends the screen assembly downward. The sieve assembly may be installed in the vibrating screening machine so that it is configured to receive the material to be screened. The screen assembly may include guide recesses configured to mate with the guides of the vibrating screening machine 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 machine having two screens, in accordance with an exemplary embodiment of the invention. The sieve assembly 82 is an alternative embodiment in which the sieve assembly has been configured to be inserted into a vibrating sifter without applying a load to the sieve assembly, i. e. the sieve assembly 82 includes a bottom portion 82A which is formed such that it mates with the base 83 of the vibrating screener. The bottom portion 82A may be formed with the screen assembly 82 or may be a separate part. The screen assembly 82 contains similar components to the screen assembly 80 containing the screen members and screen elements, but also includes a bottom portion 82A that allows it to be placed on the base 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 bottom of the sieve 82 assembly can be configured to dock with any type of docking surface of the vibrating screening machine.

In FIG. 33 is a front view of a screen assembly 85 mounted on a single screen vibrating screen machine in accordance with an exemplary embodiment of the invention. The sieve assembly 85 is an alternative embodiment in which the sieve assembly has been configured to be inserted into a vibrating sifter without applying a load to the sieve assembly, i.e. the sieve assembly 85 includes a bottom portion 85A which is formed such that it mates with the base 87 of the vibrating screener. The lower part 85A may be formed together with the screen assembly 85 or may be a separate part. The screen assembly 85 contains similar components to the screen assembly 80 containing the screen members and screen elements, but also includes a bottom portion 85A that allows it to be placed on the base 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 may simply be held in place. The bottom of the screen assembly 85 can be configured to dock with any type of docking surface of the vibrating screening machine.

In FIG. 34 is an isometric view of the end grating shown in FIG. 3 having one sieve element partially attached thereto. In FIG. 35 is an enlarged view of the highlighted portion E of the end grating shown in FIG. 34. In FIG. 34 and 35, the screen element 16 is partially attached to the end screen element 38. The screen element 16 is aligned with the screen element 38 by the elongated fastening elements 44 and the screen element fastening holes 24, so that the elongated fastening elements 44 pass through the fastening holes 24 of the sieve element and pass a little beyond the screening surface of the sieve element. As shown along the end edge portion of the screen element 16, portions of the elongated attachment elements 44 extending beyond the screening surface of the screen element melt to form beads on the screening surface of the screen element, attaching the screen element 16 to the block 38 of the end screen element.

In FIG. 36 shows a slightly concave screen assembly 91 having pyramid-shaped lattice members included in a portion of the screen assembly 91 according to an exemplary embodiment of the present invention. The screening surface of the sieve assembly may be substantially flat, concave or convex. The screen assembly 91 can be configured to bend into a predetermined shape when a compressive force is applied. Screen assembly 91 as shown in FIG. 36 contains pyramid-shaped lattice elements in the portion of the screen assembly closest to the incoming material flow on the vibratory screening machine. The part including the pyramid-shaped lattice elements provides an increased screening surface area and a directed material flow. The part of the sieve assembly closest to the discharge end of the vibrating screening machine includes flat screen elements. An area may be provided on the flat portion so that the material may dry and/or harden on

- 32 042381 sieve assembly. Various combinations of flat and pyramidal screen elements may be included in the screen assembly depending on the desired configuration and/or specific screening application conditions. Also, vibratory screening machines that use multiple screen assemblies may have individual screen assemblies in various configurations to be used together in a particular application. For example, the screen assembly 91 can be used with other screen assemblies so that it is placed near the discharge end of the vibrating screener so that it allows for the solidification and/or drying of the material.

In FIG. 37 is a flow chart showing the steps for manufacturing a screen assembly according to an exemplary embodiment of the present invention. As shown in FIG. 37, the screen manufacturer may be provided with performance specifications for the screen assembly for the screen assembly. The specifications may include at least one of the following: material requirements, screening open area, power, and/or cut-off point for the screen assembly. The manufacturer can then define screening hole requirements (shape and size) for the screen element as described in this document. The manufacturer can then define 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/or a non-flat configuration. A flat configuration can be created from center bars (18 or 418) and end bars (14 or 414). The non-planar configuration may include at least a portion of the pyramid-shaped central lattice elements (60 or 460) and/or the pyramid-shaped end lattice elements (58 or 458). The sieve elements can be produced by injection molding. The lattice element blocks may also be injection molded, but need not be injection molded. The sieve elements and lattice elements may include nanomaterial, as described herein, distributed within them. After creating both the screen elements and the grid element blocks, the screen elements can be attached to the grid element blocks. The sieve elements and the grid elements can be fastened together using bonding materials having the nanomaterial distributed within them. The screen elements can be attached to the grid elements using laser welding. A plurality of lattice element blocks may be fastened together to form support frames. The central support frames are formed from the central lattice elements and the end support frames are formed from the end lattice elements. Pyramid shaped support frames can be created from pyramid shaped trellis blocks. The support frames may be fastened such that the center support frames are at the center of the screen assembly and the end support frames are at the end of the screen assembly. The connecting strips can be attached to the screen assembly. Different screening surface areas can be formed by varying the number of pyramid-shaped screen elements included in the sieve assembly. Alternatively, the screen elements may be attached to the screen element blocks after the plurality of screen elements have been fastened together or after the plurality of support frames have been fastened together. Instead of a plurality of independent screen elements that are fastened together to form a single block, a single screen element design can be made that has the required screen assembly size. The individual screen elements can then be attached to one screen element structure.

In FIG. 38 is a flow chart showing the steps for manufacturing a screen assembly according to an exemplary embodiment of the present invention. The thermoplastic screen element can be injection molded. The grid elements can be made to receive the screen elements. The screen elements may be attached to the screen elements, and a plurality of screen assemblies may be attached to form a screening surface. Alternatively, the screen elements may be bonded to each other prior to attaching the screen elements.

In yet another exemplary embodiment, a method of screening material is provided, comprising attaching a screen assembly to a vibrating screen machine and forming an upper screening surface of the screen assembly in a concave shape, wherein the screen assembly comprises a screen element having a series of screen holes forming the screening surface of the sieve element, and a grating element containing a plurality of elongated structural elements forming a grating frame having grating openings. The sieve elements cover the openings of the grid and are attached to the upper surface of the grid element. A plurality of screen members are fastened together to form a screen assembly, and the screen assembly has a continuous screen assembly screen surface comprised of a plurality of screen element screen surfaces. The sieve element is a single piece made of injection molded thermoplastic.

In FIG. 39 is an isometric view of a vibrating sieve machine having one sieve assembly 89 with a flat screening surface mounted thereon, with part of the vibrating machine cut away, whereby the sieve assembly is shown. Sieve 89 assembly is one

- 33 042381 block, which contains the design of the lattice element and sieve elements, as described in this document. The structure of the lattice element may be a single block or may be a plurality of lattice elements fastened together. Although the screen assembly 89 is shown as a generally flat type assembly, it may be concave or convex, and may be deformable into a concave shape by a compression assembly or the like. It may also be designed to be tensioned from above or below, or may be otherwise configured to attach to various types of vibratory screening machines. Although the sieve assembly embodiment is shown to cover the entire screening base of the vibrating screening machine, the sieve assembly 89 can also be made in any desired shape or size and may cover only a portion of the screening base.

In FIG. 40 shows an isometric view of a sieve element 99 in accordance with an exemplary embodiment of the present invention. The sieve element 99 has a substantially triangular shape. The sieve element 99 is a one piece molded thermoplastic and has similar components (including screen hole sizes) to the sieve elements 16 and 416 as described herein. Alternatively, the sieve element may be rectangular, round, triangular, square, etc. Any shape can be used for the screen element and any shape can be used for the screen element, provided that the screen element has screen openings that match the shapes of the screen elements.

In FIG. 40A and 40B show the screen element structure 101, which may be a lattice type structure, with the screen elements 99 attached thereto forming a pyramidal shape. In an alternative embodiment, the completed pyramidal structure of the screen element structure 101 may be injection molded from thermoplastic as a single pyramidal shaped screen element. In the configuration shown, the screen element design has four triangular screen element screening surfaces. The bases of the two triangular screening surfaces start at the two side elements of the sieve element and the bases of the other two triangular screening surfaces start at the two end elements of the sieve element. All screening surfaces rise to a central point above the end elements and side elements of the screen element. The angle of the inclined screening surfaces can be changed. The screen element structure 101 (or alternatively individual screen element pyramids) can be attached to the screen element structure as described herein.

In FIG. 40C and 40D show screen element structures 105 with screen elements 99 attached and having descending side elements and edge elements of the pyramidal shape of the screen element structure 105. Alternatively, the entire pyramid can be injection molded from thermoplastic as a single pyramid shaped sieve element. In the configuration shown, the individual sieve elements 99 form four triangular screening surfaces. The bases of the two triangular screening surfaces start at the two side elements of the sieve element and the bases of the other two triangular screening surfaces start at the two end elements of the sieve element. All screening surfaces are lowered to a central point under the end elements and side elements of the screen element. The angle of the inclined screening surfaces can be changed. The screen element structure 105 (or alternatively individual screen element pyramids) can be attached to the screen element structure as described herein.

In FIG. 40E and 40F show the screen element structure 107 having a plurality of descending and rising side members and pyramid-shaped edge members of the screen element structure 107 . Each pyramid contains four separate sieve elements 99, but can also be formed as one sieve element pyramid. In the configuration shown, each screen element has sixteen triangular screen surfaces forming four separate pyramidal screen surfaces. The pyramidal screening surfaces can rise above or below the end elements and side elements of the screen element. The screen element structure 107 (or alternatively individual screen element pyramids) can be attached to the screen element structure as described herein. In FIG. 40-40F show only examples of variations 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 defined herein. Because the screen element is injection molded from a thermoplastic, many variations can be easily manufactured and incorporated into the various exemplary embodiments discussed herein.

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Claims (55)

In FIG. 44 shows a pre-screen design 200 for use with vibrating screeners. The pre-screen structure 200 includes a support frame 300 that is partially covered by individual pre-screen 210 assemblies. The pre-screen 210 assembly is shown having a plurality of pre-screen elements 216 mounted on the pre-screen gratings 218. Despite this, the pre-sieve 210 assemblies are shown comprising six pre-sieve screen members 218 bonded together, where different numbers and types of screen members can be bonded together to form different shapes and sizes of the pre-screen 210 assemblies. The pre-screen assembly 210 is attached to the support frame 300 and forms a continuous pre-screen surface 213. The pre-screen structure 200 may be installed over the primary screen surface. The pre-screen assemblies 210, pre-screen elements 216, and pre-screen grids 218 may include any of the components of the various screen assemblies, screen elements, and grid element designs described herein and may be configured to be mounted on a support frame 300. pre-sieve, which can have various shapes and configurations suitable for pre-sifting applications. The pre-screen structure 200, the pre-screen assemblies 210, the pre-screen elements 216, and the grid-type pre-screen elements 218 may be configured to be included in the pre-screen technologies (e.g., compatible with the installation designs and screen configurations) described in U.S. Patent Application No. 12/051658. In FIG. 44A is an enlarged view of the pre-screen assembly 210. Embodiments of the present invention described herein, including sieve elements and sieve assemblies, can be configured for use with a variety of vibratory screening machines and parts thereof, including machines designed for wet and dry applications, machines having tiered tiers and /or a plurality of screening baskets, and machines having various screen attachment arrangements such as tension mechanisms (bottom or top), squeezing mechanisms, clamping mechanisms, magnetic mechanisms, etc. For example, the sieve assemblies described in the present invention can be configured to be installed on the vibrating screening machines described in US Pat. Nos. 7,578,394; 5332101; 6669027; 6,431,366 and 6,820,748. Furthermore, the screen assemblies described herein may include: side portions or connecting strips, including U-shaped elements, configured to accommodate top-type tension elements, for example, as described in US patent No. 5332101; side portions or connecting strips including openings accommodating pins configured to receive lower-type tension elements, for example, as described in US patent No. 6669027; lateral elements or connecting strips for compression loading, for example, as described in US patent No. 7578394; or may be configured to be mounted and loaded on multi-level machines, such as those described in US Pat. No. 6,431,366. Screen assemblies and/or screen elements may also be configured to include components described in US Patent Application 12/460200, including the rail assembly technologies described therein and the preformed panel technologies described therein. Moreover, screen assemblies and screen elements can be configured to be included in the pre-screening technologies (eg, compatible with screen installations and configurations) described in US Patent Application No. 12/051658. US Patents No. 7578394; 5332101; 4882054; 4857176; 6669027; 7228971; 6,431,366 and 6,820,748 and U.S. Patent Applications Nos. 12/460,200 and 12/051,658, which are specifically incorporated herein by reference together with their related patent families and related patent applications and patent applications. The exemplary embodiments have been described above. However, it is clear that various modifications and changes can be made in addition without departing from the general spirit and scope of the invention. Accordingly, the description and graphics should be considered in an explanatory and not a restrictive sense. CLAIM 1. The sieve assembly, characterized in that it contains a sieve element containing the first material; and a screen element comprising a second material different from the first material, wherein the screen element is a single piece made from an injection molded thermoplastic, and at least one of the first material of the screen element and the second material of the screen element is fused so as to fuse the first and second materials together, thereby attaching the sieve element directly to the top surface of the screen element, wherein the sieve element has sieve openings from about 40 µm to about 150 µm, and the sieve element has an open screening area of at least 16% of total area - 35 042381 sifting element sieve. 2. A screen assembly according to claim 1, wherein the first screen element material and the second screen element material are laser welded together to attach the screen element to the screen element. 3. The sieve assembly according to claim 1, characterized in that the sieve element contains the first clutch arrangement, and the lattice element contains the second clutch arrangement, while the sieve element is attached to the lattice element by means of the first and second clutch arrangements. 4. The sieve assembly according to claim 1, characterized in that a plurality of sieve elements are attached to one lattice element to form a sieve assembly. 5. Screen assembly according to claim 3, characterized in that the first clutch arrangement and the second clutch arrangement are different materials, wherein at least one of the first clutch arrangement and the second clutch arrangement is energized, so that the screen element and the grid element fastened together. 6. Screen assembly according to claim 3, characterized in that the first engagement arrangement is a plurality of cavities on the lower surface of the screen element and the second engagement arrangement is a plurality of fused strips on the upper surface of the screen element. 7. Screen assembly according to claim 1, characterized in that the screen element contains thermoplastic polyurethane. 8. Screen assembly according to claim 1, characterized in that the screen element contains at least one of glass, nylon and carbon. 9. Screen assembly according to claim 1, characterized in that the screen element has a plurality of screen holes, which are elongated grooves with a width and length, while the width of the screen holes is from about 40 microns to about 150 microns between the inner surfaces of each element surface sieve. 10. Screen assembly according to claim 1, characterized in that the screen element contains translucent parts and the lattice element contains at least one of glass, nylon and carbon. 11. A method of screening material, characterized in that it includes attaching a sieve assembly to a vibrating screening machine; giving the upper screening surface of the sieve assembly a concave shape, while the sieve assembly contains a sieve element containing the first material and having a sequence of screening holes forming the screening surface of the sieve element, while the sieve element has an open screening area of at least 16% of total screening area of the sieve element; and a grating element containing a second material different from the first material, and containing a plurality of elongated structural elements forming a lattice frame having lattice openings, while the sieve element covers the lattice openings, while at least one of the first material of the sieve element and the second material of the screen element is melted so as to fuse the first and second materials together, thereby attaching the screen element directly to the upper surface of the screen element, while a plurality of screen elements are fastened together to form a screen assembly and the screen assembly has a continuous screening surface of the screen assembly, which contains a plurality of screening surfaces of the sieve element, while the sieve element is a single part obtained from a thermoplastic injection molding; and screening the material using the sieve assembly. 12. The method according to claim 11, characterized in that the sieve element comprises an edge portion and the sieve element has sieve surface elements forming a sequence of screening holes. 13. The method of claim 12, wherein the sieve surface elements are elongated elements forming a series of screening holes, wherein the screening holes are elongated slots having a distance between the inner surfaces of each sieve surface element of the sieve surface elements of from about 43 µm to about 1000 µm. 14. The method of claim 12, wherein the screen surface elements are elongated elements forming a series of screening holes, wherein the screening holes are elongated slots having a distance between the inner surfaces of each screen surface element of the screen surface elements of from about 70 µm to about 180 µm. 15. The method of claim 12, wherein the sieve surface elements are elongated elements forming a series of screening holes, wherein the screening holes are elongated slots having a distance between the inner surfaces of each sieve surface element of the sieve surface elements of from about 43 µm to approximately 106 µm. 16. The method according to claim 12, characterized in that the screening holes are elongated slots having essentially the same width and length, essentially the same width has a value in the range from about 0.044 mm to about 4 mm, and the length has a value of - 36 042381 range from about 0.088 mm to about 60 mm. 17. The method of claim 12, wherein the screen element assembly further comprises a pair of substantially parallel end portions, a pair of substantially parallel side edge portions substantially perpendicular to the end portions, a first support member for the screen element; a second screen element support extending orthogonally to the first screen element support, wherein the first screen element support extends between the end portions and is approximately parallel to the side edge portions, the second screen element support extends between the side edge portions and is approximately parallel to the end portions ; and wherein the screen element assembly comprises a first sequence of reinforcing elements substantially parallel to the side edge portions; a second sequence of reinforcing elements substantially parallel to the end portions, wherein the screen surface elements extend parallel to the end portions, wherein the end portions, side edge portions, first and second support members, the first reinforcing member sequence, and the second reinforcing member sequence provide structural stability to the surface members sieves and screening holes. 18. The method of claim 12, wherein the screen element further comprises a screen element attachment assembly molded together with the screen element and configured to mate with the grid element attachment arrangement. 19. A method for manufacturing a sieve assembly for screening materials, characterized in that it includes injection molding a sieve element containing a first material, wherein the sieve element contains a screening surface of the sieve element having screening holes, while the screening surface of the sieve element has an open screening area, constituting at least 16% of the total screening area of the screening surface of the sieve element; manufacture of a grid element that supports a sieve element containing a second material different from the first material, wherein the grid element has a grid frame with grid openings, the sieve element covers at least one grid opening, while at least one of the sieve elements and the grid element are one piece made from injection molded thermoplastic; and attaching the screen element directly to the upper surface of the screen element by melting at least one of the first material and the second material so as to fuse the first and second materials together, the screen assembly has a continuous screening surface of the screen assembly, which contains a plurality of screening surfaces of the element sieves. 20. The method of claim 19, further comprising attaching a first bonding strip to a first end of the screen assembly and attaching a second bonding strip to a second end of the screen assembly, wherein the first and second bonding strips connect the screen elements together. 21. The method according to claim 20, characterized in that the connecting strip is adapted to distribute the load on the first and second ends of the sieve assembly. 22. The method of claim 19, wherein the sieve element comprises sieve surface elements forming screen openings, wherein the screen openings are elongated slots having a distance between the inner surfaces of each sieve surface element of from about 43 µm to about 1000 µm . 23. The method according to claim 19, characterized in that the sieve element contains elements of the sieve surface that form screen holes, and the screen holes are elongated grooves having a distance between the inner surfaces of each element of the sieve surface, ranging from about 70 microns to about 180 microns . 24. The method according to claim 19, characterized in that the sieve element contains elements of the sieve surface that form screen holes, and the screen holes are elongated grooves having a distance between the inner surfaces of each element of the sieve surface, ranging from about 43 microns to about 106 microns . 25. The method according to claim 19, characterized in that the sieve element contains elements of the sieve surface that form screening holes, and the screening holes are elongated grooves having a width and length, and the width is from about 0.044 mm to about 4 mm, and the length is from about 0.088 mm to about 60 mm. 26. The method according to claim 19, characterized in that the grating element comprises at least one base element having fasteners that mate with the fasteners of the remaining base elements of the remaining lattice elements, and fasten the lattice elements together. 27. The method of claim 26 wherein the fasteners are latches and latch holes that snap and securely fasten the gratings together. 28. Screen assembly, characterized in that it contains a screen element obtained by injection molding containing the first material; And - 37 042381 grating element obtained by injection molding, containing a second material different from the first material, while the sieve element is attached directly to the upper surface of the lattice element by melting at least one of the first material of the sieve element and the second material of the lattice element by laser welding so as to fuse the first and second materials together. 29. A sieve assembly according to claim 28, wherein the sieve element contains substantially pure thermoplastic polyurethane. 30. The sieve assembly according to claim 28, characterized in that the sieve element contains a sequence of screening holes. 31. The screen assembly according to claim 28, wherein the screen assembly has a first engagement arrangement on the bottom surface of the screen element and the screen element has a second engagement arrangement on the top surface of the screen element. 32. The screen assembly according to claim 31, wherein the first engagement arrangement is a plurality of cavities and the second engagement arrangement is a plurality of alloy strips. 33. Screen assembly according to claim 32, characterized in that the plurality of cavities are configured to dock with the plurality of alloy strips. 34. Screen assembly according to claim 32, characterized in that the fused strips contain at least one of carbon and graphite material. 35. Screen assembly according to claim 28, characterized in that the screen element has a sequence of screening holes. 36. Screen assembly according to claim 35, characterized in that the screen holes are elongated grooves with a width and length, while the width of the screen holes is from about 43 microns to about 1000 microns. 37. A method of screening material, characterized in that it includes attaching a sieve assembly to a vibrating screening machine, while the sieve assembly contains a sieve element containing the first material and having a sequence of screening holes forming the screening surface of the sieve element, and a lattice element containing the second a material other than the first material, wherein the screen element is attached directly to the top surface of the screen element by laser welding, which fuses at least one of the first material of the screen element and the second material of the screen element so as to fuse the first and second materials together, when in this case, a plurality of screen elements are fastened together to form a sieve assembly, and the sieve assembly has a continuous screening surface of the sieve assembly containing a plurality of screening surfaces of the sieve element, while the sieve element is a single part obtained from injection molded thermoplastic iem; and screening the material using the screen assembly. 38. The method according to claim 37, characterized in that the sieve element comprises an edge portion and the sieve element has sieve surface elements forming a sequence of screening holes. 39. The method of claim 38, wherein the sieve surface elements are elongated elements forming a sequence of screening holes, wherein the screening holes are elongated grooves having a distance between the inner surfaces of each sieve surface element of the sieve surface elements of from about 43 µm to about 1000 µm. 40. The method of claim 38, wherein the sieve surface elements are elongated elements forming a series of screening holes, wherein the screening holes are elongated slots having a distance between the inner surfaces of each sieve surface element of the sieve surface elements of from about 70 µm to about 180 µm. 41. The method of claim 38, wherein the sieve surface elements are elongated elements forming a sequence of screening holes, wherein the screening holes are elongated slots having a distance between the inner surfaces of each sieve surface element of the sieve surface elements of from about 43 µm to approximately 106 µm. 42. The method of claim 38, wherein the screening holes are elongated slots having substantially the same width and length, substantially the same width is in the range from about 0.044 mm to about 4 mm, and the length is in the range from about 0.088 mm to about 60 mm. 43. The method according to claim 38, characterized in that the lattice element of the sieve assembly further comprises a pair of essentially parallel end parts, a pair of essentially parallel side edge parts, essentially perpendicular to the end parts, the first support element for element - 38 042381 and sieves; a second screen element support extending orthogonally to the first screen element support, wherein the first screen element support extends between the end portions and is approximately parallel to the side edge portions, the second screen element support extends between the side edge portions and is approximately parallel to the end portions ; and wherein the screen element assembly comprises a first sequence of reinforcing elements substantially parallel to the side edge portions; a second sequence of reinforcing elements substantially parallel to the end portions, wherein the screen surface elements extend parallel to the end portions, wherein the end portions, side edge portions, first and second support members, the first reinforcing member sequence, and the second reinforcing member sequence provide structural stability to the surface members sieves and screening holes. 44. The method of claim 38, wherein the screen element further comprises a screen element attachment assembly molded together with the screen element and configured to mate with the grid element attachment arrangement. 45. A method of manufacturing a sieve assembly for screening materials, characterized in that it includes injection molding a sieve element containing a first material, the sieve element comprising a screening surface of the sieve element having screening holes; manufacturing a grating element that supports a sieve element containing a second material different from the first material; and attaching the screen element directly to the upper surface of the screen element by laser welding, which fuses at least one of the first material of the screen element and the second material of the screen element so as to fuse the first and second materials together, the screen assembly has a continuous screening surface of the screen in assembly, which contains a plurality of screening surfaces of the sieve element. 46. The method of claim 45, further comprising attaching a first bonding strip to a first end of the screen assembly and attaching a second bonding strip to a second end of the screen assembly, wherein the first bonding band and the second bonding band connect the screen elements together. 47. The method according to claim 46, characterized in that the first connecting strip is configured to distribute the load over the first end of the sieve assembly and the second end of the sieve assembly. 48. The method of claim 45, wherein the sieve element comprises sieve surface elements forming screen openings, wherein the screen openings are elongated grooves having a distance between the inner surfaces of each sieve surface element of the sieve surface elements of from about 43 µm to approximately 1000 µm. 49. The method of claim 45, wherein the sieve element comprises sieve surface elements forming a sequence of sieving holes, wherein the sieving holes are elongated grooves having a distance between the inner surfaces of each sieve surface element of the sieve surface elements of from about 70 µm up to about 180 µm. 50. The method of claim 45, wherein the sieve element comprises sieve surface elements forming a sequence of sieving holes, wherein the sieving holes are elongated grooves having a distance between the inner surfaces of each sieve surface element of the sieve surface elements, ranging from about 43 microns up to about 106 µm. 51. The method according to claim 45, characterized in that the sieve element contains elements of the sieve surface that form screen holes, and the screen holes are elongated grooves having essentially the same width and length, essentially the same width has a value in the range of approximately 0.044 mm to about 4 mm, and the length has a value in the range from about 0.088 mm to about 60 mm. 52. The method according to claim 45, characterized in that at least one of the sieve elements or the grid element is a single piece made from an injection molded thermoplastic. 53. The method according to claim 45, wherein the grid element comprises at least one base element having first fasteners that mate with second fasteners of the second base elements of the second lattice elements and fasten the lattice element and the second lattice elements together. 54. The method of claim 53, wherein the first fasteners are latches and the second fasteners are latch holes that snap into place and securely fasten the grill element and the second grill elements together. 55. The method of claim 45, wherein the sieve element comprises a sieve element attachment arrangement configured to mate with the grid element attachment arrangement. -