System and methods for improving flow through fluid filters

Abstract

In some embodiments, the disclosure is directed to a wire screen system comprising one or more thick and thin wires arranged in an alternating configuration and coupled to supporting rods. In some embodiments, each of the thin wires is approximately 50% or less the thickness of the thick wires at their respective bases. The screen system may take on various forms, such as flat, curved, or cylindrical. In some embodiments, the cylindrical tube is separable into two halves. The thick, thin, and / or short wires may feature a wedge profile, narrowing toward the supporting rods, with the base oriented to face the direction of flow. In some embodiments, short wires, which may be approximately 50% or less the length of the thick and / or thin wires, may be interspersed. In cylindrical configurations, wire widths may taper inward toward the centerline, enhancing the ability of the screen to stay free of debris.

Description

SYSTEM AND METHODS EOR IMPROVING FLOW THROUGH FLUID FILTERSBACKGROUND

[0001] Industrial sieves and screens are used in various sectors, including mining, wastewater treatment, and food processing, for filtering or trapping particles. These devices are employed to separate particles based on size, ensuring the quality and purity of materials. Traditional sieving and screening methods have utilized wedge profiled wires of uniform thickness to create the necessary apertures for filtration. However, such designs often result in larger total screen areas, which can be less efficient and more costly.

[0002] Centrifuge baskets, filter elements, and related products have similarly relied on conventional screen designs that do not offer optimal performance. Precise aperture dimensions for effective separation and filtration are paramount, yet achieving this precision with standard thick wedge profiled wires can be challenging. Additionally, maintaining clean screen surfaces to prevent clogging and ensure consistent operation requires regular maintenance.

[0003] FIG. 1 illustrates an isometric view of a prior art segment of a wedge wire screen flat panel according to some embodiments. In some embodiments, the wedge wire screen flat panel comprises a plurality of thick wedge wires 105 arranged in parallel and joined onto a set of supporting rods 106. In this example, the thick wedge wires 105 are of uniform height 104 and width. This can lead to inefficiencies in both material usage and operational performance.

[0004] There exists, therefore, a need for improved sieve and screen designs that offer precise aperture dimensions while reducing the total screen area needed for a given flow throughput. Additionally, there is a need for screen structures that can maintain cleanliness through innovative methods, thereby reducing the frequency and intensity of maintenance required to keep the screens free from debris and other unwanted matter.SUMMARY

[0005] In some embodiments, the disclosure is directed to a wire screen system comprising one or more of a plurality of thick wires, a plurality of thin wires, and a plurality of supporting rods. In some embodiments, each of the plurality of thin wires are approximately 50% or less of a thickness of each of the plurality of thick wires at a respective base. In some embodiments, the plurality of thick wires and the plurality of thin wires are arranged in an alternating configuration.In some embodiments, the plurality of thick wires and the plurality of thin wires are coupled to the plurality of supporting rods in the alternating configuration.

[0006] In some embodiments, the wire screen is arranged as a flat panel. In some embodiments, the wire screen is arranged as a curved panel. In some embodiments, the wire screen is arranged as a cylindrical tube. In some embodiments, the cylindrical tube is separable into a first half and a second half.

[0007] In some embodiments, each of the plurality of thin wires are approximately a same length as each of the plurality of thick wires. In some embodiments, each of the plurality of thick wires includes a wedge profile. In some embodiments, a base of each wedge profile is configured to face a flow direction. In some embodiments, the wedge profile narrows from the base to the plurality of supporting rods. In some embodiments, each of the plurality of thin wires are approximately 50% or less of a length of each of the plurality of thick wires. In some embodiments, each of the plurality of thin wires are approximately 33% or less of the length of each of the plurality of thick wires.

[0008] In some embodiments, each of the plurality of thin wires comprise a different profile than each of the plurality of thick wires. In some embodiments, each of the plurality of thin wires comprise a wedge profile. In some embodiments, there are no spacing protrusions between each of the plurality of thick wires and each of the plurality of thin wires. In some embodiments, the wire screen system includes spacing protrusions between each of the plurality of thick wires and each of the plurality of thin wires. In some embodiments, each of the spacing protrusions is formed as part of a respective thin wire. In some embodiments, each of the spacing protrusions are configured to couple a thin wire to an adjacent thick wire.

[0009] In some embodiments, the wire screen system includes a plurality of short wires. In some embodiments, each of the plurality of short wires are approximately 50% or less a length of the plurality of thick wires and the plurality of thin wires. In some embodiments, each of the plurality of short wires are approximately the same length. In some embodiments, each of the plurality of short wires are positioned between a thick wire and a thin wire in the alternating configuration. In some embodiments, the wire screen is arranged as a hollow cylinder. In some embodiments, a width of each of the plurality of thick wires, the plurality of thin wires, and the plurality of short wires decrease as each extend toward a centerline of the hollow cylinder.DESCRIPTIONS OF THE DRAWINGS

[0010] The features, and advantages of the disclosure will be apparent from the following description of embodiments as illustrated in the accompanying drawings, in which reference characters refer to the same parts throughout the various views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating principles of the disclosure:

[0011] FIG. 1 illustrates an isometric view of a conventional wedge wire screen flat panel.

[0012] FIG. 2 shows an isometric view of a segment of a wedge wire screen flat panel configuration, in accordance with some embodiments.

[0013] FIG. 3 depicts an isometric view of a segment of a wedge wire screen flat panel, in accordance with some embodiments.

[0014] FIG. 4 illustrates an isometric view of a segment of a wedge wire screen flat panel, featuring an advanced design where a combination of tall and short thin wedge wires are interposed between tall thick wedge wires, in accordance with some embodiments.

[0015] FIG. 5 depicts a partial cut-away, isometric view of a wedge wire screen tube, in accordance with some embodiments.

[0016] FIG. 6 illustrates an isometric view of a wedge wire screen tube comprising two distinct screen sub-sections within a single assembled unit, in accordance with some embodiments.DETAILED DESCRIPTION

[0017] The present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, which form a part hereof, and which show, by way of non-limiting illustration, certain example configurations of wedge wire screen structures in accordance with some embodiments. Subject matter may, however, be embodied in a variety of different forms, as well as combinations of features depicted in non-limiting configurations. Therefore, covered or claimed subject matter is intended to be construed as not being limited to any example configuration of structures or function set forth herein.

[0018] Example configurations, which borrow from portions of the system as a whole, are provided merely to show how one of ordinary skill would make and use the system using some embodiments of the present disclosure. Likewise, a broad scope for claimed or covered subject matter is intended. Among other things, for example, subject matter may be embodied as methods, devices, components, filtration assemblies, and / or structural configurations. Accordingly, someembodiments may, for example, take the form of hardware, manufacturing processes, or any combination thereof. The following detailed description is, therefore, not intended to be taken in a limiting sense.

[0019] As used throughout the specification and claims, terms may carry nuanced meanings that are informed by context and are not limited to explicitly stated definitions. The phrase “in some embodiments” is not intended to refer exclusively to the same embodiment or to distinct embodiments, unless clearly indicated. Furthermore, the absence of the phrase “in some embodiments” in a sentence should not be interpreted to mean that the described subject matter cannot be combined with or omitted from other elements or embodiments described in relation to other text and / or figures presented herein when defining the metes and bounds of the system. Thus, the system may be described using any combination of the features described herein.

[0020] In general, terminology may be understood at least in part from usage in context. For example, terms such as “and,” “or,” or “and / or,” as used herein may include a variety of meanings that may depend at least in part upon the context in which such terms are used. Typically, “or” if used to associate a list, such as A, B or C, is intended to mean A, B, and C, here used in the inclusive sense, as well as A, B, or C, here used in the exclusive sense.

[0021] In addition, the term “one or more” as used herein, depending at least in part upon context, may be used to describe any feature, structure, or characteristic in a singular sense or may be used to describe combinations of features, structures or characteristics in a plural sense.

[0022] Similarly, terms such as “a,” “an,” or “the,” again, may be understood to convey a singular usage or to convey a plural usage, depending at least in part upon context. In addition, the term “based on” may be understood as not necessarily intended to convey an exclusive set of factors and may, instead, allow for existence of additional factors not necessarily expressly described, again, depending at least in part on context.

[0023] As used herein, “can” or “may” or derivations thereof (e.g., the screen may filter particles larger than size X) are used for descriptive purposes only and are understood to be synonymous and / or interchangeable with “configured to” (e.g., the screen is configured to filter particles larger than size X) when defining the metes and bounds of the system. In addition, the terms “can” or “may” may be used to denote the modularity of the system, where different portions of the screen structure described in relation to various figures can be included, excluded, or combined with other features described herein when defining the metes and bounds of the system.

[0024] As used herein, terms such as “thin,” “thick,” “tall,” “short,” “greater,” and “lesser” are used to describe components in relation to other similar-functioning components depicted in some embodiments. For example, a “thin” wedge wire profile is thinner than a “thick” wedge wire profile shown in the same drawing and / or serving a similar filtration function. Likewise, a “short” profile is shorter in height than a “tall” profile within some embodiments. This these descriptors distinguish between elements based on their relative proportions and roles within a given configuration. As used herein, a thin wire is less than or equal to 50% the thickness of a thick wedge wire 204 at their respective surfaces opposite the supporting rod, also referred to as the base. Similarly, a short wire is less than or equal to 50% the vertical length, extending perpendicular to the base, of a short wire. Other ranges may be recited in relation to different figures, but these ranges can be applied to any configuration described herein when defining the metes and bounds of the system.

[0025] As used herein, the terms “slot” and “aperture” are used interchangeably to describe the space or gap formed between adjacent wedge wires through which fluid or particulate matter may pass. This interchangeable usage reflects the functional equivalence of the terms in the context of wedge wire screen filtration.

[0026] As used herein, the term “wire” is not limited to a traditional cylindrical or metallic filament but is intended to encompass any elongated structural element used in the construction of the screen. This includes, but is not limited to, wedge-shaped, rectangular, or other profiled crosssections formed from metal, polymer, composite, or other suitable materials. The term “wire” is used for consistency with industry terminology, but it is understood to include any elongated member configured to perform the described filtration, spacing, or structural functions within the screen assembly.

[0027] As used herein, the term “wedge” is employed to describe the general shape or profile of a wire or structural element as depicted in the figures and described in some embodiments. However, the use of the term “wedge” is not intended to be limiting. When defining the metes and bounds of the disclosure, the term “wedge” may be replaced by any other shape described herein, including but not limited to trapezoidal, rectangular, curved, other non-tapered forms, or combinations thereof, as non-limiting examples.

[0028] As used herein, the term “rods” refers to the structural elements that support and secure the wedge wires in the screen assembly. The term is not limited to cylindrical or round cross-sections,nor to any particular material. “Rods” may include any elongated support members having polygonal, rectangular, oval, or other suitable cross-sectional shapes, and may be formed from metal, polymer, composite, or other structurally appropriate materials. The use of “rods” is intended to describe the function of these elements in providing structural integrity and alignment for the wedge wires, and is not limited to any specific geometry or composition when defining the metes and bounds of the disclosure.

[0029] FIG. 2 illustrates an isometric view of a segment of a wedge wire screen 200 comprising thin wedge wires 203 in-between thick wedge wires 204, in accordance with some embodiments. Flow direction 201 denotes the intended direction of fluid or slurry movement through the screen slots. In some embodiments, the flow direction may also correspond to the taper of one or more wedge wire cross-sections.

[0030] In some embodiments, the wedge wire screen 100 includes a series of alternating thick 204 and thin 203 wedge wires, wherein the thin wedge wires 203 are placed adjacent and in-between the thick wedge wires 204. In some embodiments, the thick wedge wires 204 and thin wedge wires 203 are joined onto a set of supporting rods 202 that extend perpendicularly to the wedge wires, maintaining a desired precise dimension of apertures 205 between the juxtaposed thin wedge wires 203 and thick wedge wires 204. In some embodiments, the thin wedge wires 203 are less than or equal to 50% the thickness of a thick wedge wire 204 at their base. In some embodiments, the thin wedge wires 203 are less than or equal to 33% the thickness of a thick wedge wire 204 at their base.

[0031] In some embodiments, the thin wedge wires 203 have a smaller width compared to the thick wedge wires 204, resulting in a smaller total screen area for the same total aperture area when compared to wedge wire screens 100 composed solely of thick wedge wires 204 (see FIG. 1, prior art). In some embodiments, the precise dimension of the apertures 205 is maintained through the use of manufacturing techniques that ensure consistent spacing between the wedge wires, which may include welding, soldering, and / or other forms of attachment.

[0032] In some embodiments, the wedge wire screen 100 is manufactured using precision fabrication techniques that ensure consistent spacing and secure attachment of the thick wedge wires 204 and thin wedge wires 203 to the supporting rods 202. These techniques may include welding processes such as resistance welding or laser welding, which allow for accurate placement and bonding of each wedge wire to the supporting rods 202. In other embodiments, soldering orbrazing may be employed, particularly for materials requiring lower thermal input. The use of jigs or fixtures during assembly may further assist in maintaining uniform aperture dimensions 205 across the wedge wire screen 100. These manufacturing methods contribute to the structural integrity, dimensional accuracy, and long-term durability of the wedge wire screen 100.

[0033] In some embodiments, the alternating arrangement of thick wedge wires 204 and thin wedge wires 203 is configured to optimize both structural support and filtration efficiency. The wedge-shaped cross-section of the thick wedge wires 204 and / or thin wedge wires 203 taper in the direction of flow. The thick wedge wires 204 provide mechanical strength and rigidity to the wedge wire screen 100, while the thin wedge wires 203 reduce the overall material usage and screen surface area without compromising the total open area available for fluid or particle passage. The alternating configuration also enables more apertures within a given area without losing the benefits of the shape of the thick wedge wires with regard to output flow. This enables a balance between durability and throughput, particularly in applications where fine particle separation is required.

[0034] In some embodiments, the supporting rods 202 are configured to provide structural integrity to the wedge wire screen 100, and the cross-sectional profile of these supporting rods 202 can vary to include polygonal, round, and / or other suitable shapes. In some embodiments, the supporting rods 202 may be of the same or different cross-sectional profiles within the same wedge wire screen 100. The combination of thick wedge wires 204 and thin wedge wires 203, according to some embodiments, allows for a more efficient use of material and improves the filtration performance of the wedge wire screen 100.

[0035] FIG. 3 illustrates an isometric view of a segment of a wedge wire screen 300 comprising short-thin wedge wires 302 in-between tall-thick wedge wires 303, according to some embodiments. In some embodiments, the wedge wire screen 300 includes a plurality of short-thin wedge wires 302 positioned adjacent to and in-between tall-thick wedge wires 303. In some embodiments, these wedge wires 302, 303 are joined onto a set of supporting rods 304 that extend perpendicularly to the wedge wires, ensuring a precise dimension of slots 305 between the wedge wires for filtration purposes. In some embodiments, the use of short-thin wedge wires 302 interspersed between tall-thick wedge wires 303 is configured to reduce the total screen surface area while maintaining the same total aperture area.

[0036] In some embodiments, the short-thin wedge wires 302 include spacing protrusions 301 (e g., bumps, fasteners, etc.) spaced along the length of the wedge wire. In some embodiments, these spacing protrusions 301 serve to maintain a consistent and / or precise slot 305 dimension between the adjacent tall-thick wedge wires 303. In some embodiments, the spacing protrusions 301 are configured to facilitate a press fit or welded joint, providing a secure attachment between the short-thin wedge wires 302 and tall-thick wedge wires 303, and ensuring the structural integrity of the wedge wire screen 300. In some embodiments, the wedge wires include rods or other elongated structures inserted and / or fixed between wires to provide consistent slot 305 dimensions.

[0037] In some embodiments, spacing protrusions 301 are configured to facilitate a variety of mechanical and metallurgical connections between the short-thin wedge wires 302 and the adjacent tall-thick wedge wires 303. Spacing protrusions 301 may be shaped or positioned to enable a press-fit connection, where the short-thin wedge wire 302 is frictionally secured between adjacent tall-thick wedge wires 303 without the need for additional bonding.

[0038] In some embodiments, spacing protrusions 301 may include integral or removable fasteners. For example, integral fasteners may include molded or machined tabs, barbs, or dovetail features that are formed as part of the wedge wire profile itself. Removable fasteners may include pins, clips, or threaded inserts that engage with corresponding recesses or slots in the adjacent wedge wires. These fastening features may be used alone or in combination with welding or adhesive bonding to provide a secure and stable connection, depending on the desired level of permanence, ease of assembly, or serviceability.

[0039] Spacing protrusions 301 may serve as weld points, allowing for spot welding, resistance welding, or laser welding to permanently affix the short-thin wedge wires 302 to the tall-thick wedge wires 303. Spacing protrusions 301 may be used in brazing or soldering operations, particularly when joining dissimilar metals or when lower-temperature bonding is preferred. Additionally, spacing protrusions 301 may be configured to engage with mechanical interlocks, such as notches or grooves formed in the adjacent wedge wires, providing a snap-fit or keyed engagement that enhances alignment and structural stability. In some embodiments, spacing protrusions 301 are formed integrally with the short-thin wedge wires 302, while in some embodiments, they may be formed as part of the adjacent tall-thick wedge wires 303, or both. This flexibility in attachment allows for adaptation to different manufacturing processes, materials, and performance requirements.

[0040] The supporting rods 304 depicted in FIG. 3 provide a framework to support the wedge wires and maintain the overall structure of the wedge wire screen 300. As mentioned in relation to FIG. 2, the supporting rods 304 may have various cross-sectional profiles, which, in some embodiments, can be selected based on the specific application requirements or manufacturing considerations. The cross-sectional profiles of the supporting rods 304 can be uniform or varied within the same wedge wire screen 300 in some embodiments to optimize performance and durability.

[0041] The wedge wire screen 300 shown in FIG. 3 may be manufactured using welding techniques that allow for the secure attachment of both tall-thick wedge wires 303 and short-thin wedge wires 302 to the supporting rods 304. In some embodiments, the spacing protrusions 301 are used as alignment features during assembly, ensuring consistent slot 305 dimensions across the panel. Automated welding or brazing systems may be employed to maintain tight tolerances and repeatability, particularly in high-throughput manufacturing environments.

[0042] The combination of short-thin wedge wires 302 with tall-thick wedge wires 303, as shown in FIG. 3, results in a smaller total screen area with the same aperture area compared to a the wedge wire screen 100 composed solely of tall-thick wedge wires 105 (see FIG. 1). The arrangement allows for more efficient material usage and can enhance the filtration efficiency of the wedge wire screen 300.

[0043] Referring now to FIG. 4, an isometric view of a segment of a wedge wire screen 400 is illustrated according to some embodiments. In some embodiments, the wedge wire screen 400 includes a plurality of tall-thick wedge wires 402, interspersed with both tall-thin wedge wires 401 and short-thin wedge wires 403, all of which are joined onto a set of supporting rods 405.

[0044] Positioned in-between the tall-thick wedge wires 402 are the tall-thin wedge wires 401 in accordance with some embodiments. In some embodiments, these tall-thin wedge wires 401 are of a similar height to the tall-thick wedge wires 402, contributing to the contact area of the supporting surface of the sieve or screen. In some embodiments, the tall-thin wedge wires 401 may be shorter than the tall-thick wedge wires 402 by approximately 25%. In some embodiments, the short-thin wedge wires 403 are at least 50% of the length of the tall-thick wedge wires 402. In some embodiments, the short thin wedge wires 403 have approximately the same width as the tall thin wedge wires at their respective bases. In some embodiments, the tall-thin wedge wires 401are set at a desired precise dimension of apertures 406 between the adjacent tall-thick wedge wires 402.

[0045] In some embodiments, short-thin wedge wires 403 are of a lesser height compared to both the tall-thick wedge wires 402 and tall-thin wedge wires 401. The short-thin wedge wires 403 are strategically placed to maintain a desired precise dimension of apertures 406 between them and the adjacent tall-thick wedge wires 402 and tall-thin wedge wires 401, according to some embodiments. The presence of these short-thin wedges 403 contributes to the overall efficiency of the screen by reducing the total screen area needed for a given flowrate while maintaining the same total aperture area and / or filter size.

[0046] While certain wedge wire heights and widths are shown for illustrative purposes, in some embodiments, such heights and widths (as well as spacings) can be varied based on operational considerations as desired. As discussed above, in some embodiments, the tall-thin wedge wires 401 and the tall-thick wedge wires 402 are not necessarily of equal height. In some embodiments, the tall-thin wedge wires 401 may be shorter than the tall-thick wedge wires 402, while in other embodiments, the tall-thin wedge wires 401 may be taller than the tall-thick wedge wires 402. In either case, both the tall-thin wedge wires 401 and the tall-thick wedge wires 402 are configured to be taller than the short-thin wedge wires 403.

[0047] In some embodiments, each of the short-thin wedge wires 403 is equipped with spacing protrusions 404, spaced along the length of the wedge wire, which may have the same or similar features as spacing protrusions 301 and / or connection methos as described in relation to FIG. 3. In some embodiments, these spacing protrusions 404 facilitate a secure attachment, whether by a press fit or welded joint, in-between the taller height tall-thick wedge wires 402 and tall-thin wedge wires 401. The incorporation of these spacing protrusions 404 in some embodiments ensures that the precise dimensions of apertures 406 are consistently maintained throughout the structure, thereby improving the screening process. In some embodiments of the screen assembly 400, the spacing protrusions / bumps are on the tall-thin wedge wire 401 only, where the short-thin wedge wires 403 do not have the spacing protrusions 404.

[0048] Similar to FIGs. 2 and 3, the supporting rods 405 function as the backbone of the sieve or screen assembly, providing structural integrity and facilitating the attachment of the wedge wires, in accordance with some embodiments. In some embodiments, the supporting rods 405 mayexhibit various cross-sectional profiles, such as polygonal or round, and may be uniform or varied across the assembly to meet specific requirements.

[0049] In some embodiments, the slot 406 formed between adjacent wedge wires dictates the size of particles that can pass through the sieve or screen, ensuring that only particles of a desired size are filtered through the assembly. The arrangement of tall-thick wedge wires 402 with interspersed tall-thin wedge wires 401 and / or short-thin wedge wires 403, all secured to supporting rods 405, achieves a balance between structural robustness and screening efficiency.

[0050] Referring to FIG. 5, a partial cut-away, isometric view of a wedge wire screen tube 500 is depicted according to some embodiments. Similar to the configurations shown in FIG. 2 through FIG. 4, the wedge wire screen tube 500 comprises tall-thick wedge wires 503 and short-thin wedge wires 502 interspersed between the tall-thick wedge wires 503. In some embodiments, any wedge wire screen structure described herein can be curved or formed into a cylinder, tube, cage, or conic shape, depending on the application.

[0051] In some embodiments, the tall-thick wedge wires 503 are joined onto a set of supporting rods 501 that extend longitudinally along the length of the wedge wire screen tube 500. The supporting rods 501 may be configured with various cross-sectional profiles, including but not limited to polygonal and / or round, according to some embodiments.

[0052] The tall-thin wedge wires 503 are positioned adjacent to the tall-thick wedge wires 503 and are of a similar height, contributing to the uniformity of the working surface of the sieve or screen in some embodiments. In some embodiments, the short-thin wedge wires 502 are placed inbetween the tall-thick wedge wires 503 and are of a lesser height, configured to maintain a desired precise dimension of apertures 504 between them.

[0053] In some embodiments, the short-thin wedge wires 502 include spacing protrusions along their length similar to FIG. 3 In some embodiments, at least some wires do not include spacing protrusions such as illustrated in FIG. 2.

[0054] In some embodiments, the wedge wire screen tube 500 is formed into a cylindrical shape, with the profile length of the screen structure being parallel to the tube center axis. The cylindrical form factor allows for the screen to be used in various industrial applications where radial filtration is required.

[0055] In some embodiments, the screen structure may be comprised of two or more screen subsections in a joined assembly, providing modularity and ease of maintenance or replacement. Insome embodiments, one or more sub-sections are configured to be detachable or permanently affixed depending on the requirements of the application.

[0056] The wedge wire screen tube 500 is configured to provide efficient filtration, with the slots 504 formed between adjacent wedge wires such as the short-thin wedge wires 502 and the tall- thick wedge wires 503, dictating the size of particles that can pass through, ensuring that only particles of a desired size range are filtered through the assembly.

[0057] In some embodiments, the wedge wire screen tube 500 is incorporated with one or more stationary brushes, a moving screen, or one or more moving brushes and a stationary screen, (not shown) to enable brush sweeping action across the outside and / or inside surface areas of the screen. These features keep the screen free of debris and / or unwanted matter, thereby maintaining the efficiency and longevity of the screen in operation.

[0058] Referring now to FIG. 6, a cross-sectional view of a wedge wire screen tube 600 is depicted according to some embodiments. As mentioned previously, various elements of different figures may be combined. For example, the use of short-thin wedge wires with spacing protrusions as shown in FIG. 3 or arrangements in FIGs. 4 or 5 may be incorporated into the split cylindrical configuration of FIG. 6. The wedge wire screen tube 600, in this non-limiting example, is illustrated as comprising an arrangement of tall-thick wedge wires 602, interspersed with both tall- thin wedge wires 601 and short-thin wedge wires 603, all of which are affixed onto a set of supporting rods 604 in accordance with some embodiments.

[0059] In some embodiments, the tall-thick wedge wires 602 are characterized by their substantial height relative to the base of the supporting rods 604, providing a robust structure for the sieve or screen. In some embodiments, these tall-thick wedge wires 602 serve as the primary filtration elements, with their vertical orientation relative to the supporting rods 604, similar to the configuration shown in FIG. 4.

[0060] Positioned in-between the tall-thick wedge wires 602 are the tall-thin wedge wires 601 in accordance with some embodiments. These tall-thin wedge wires 601 are of a similar height to the tall-thick wedge wires 602, contributing to the uniformity of the working surface of the sieve or screen. In some embodiments, the tall-thin wedge wires 601 are configured to maintain a desired precise dimension of apertures 605 between them and the adjacent tall-thick wedge wires 602, as described in FIG. 4.

[0061] In some embodiments, the wedge wire screen tube 600 includes short-thin wedge wires 603. These short-thin wedge wires 603 are of a lesser height compared to both the tall-thick wedge wires 602 and tall-thin wedge wires 601. The short-thin wedge wires 603 are strategically placed to maintain a desired dimension of apertures 605 between the adjacent tall-thick wedge wires 602 and tall-thin wedge wires 601. The presence of these short-thin wedge wires 603 contributes to the overall efficiency of the screen by reducing the total screen area while maintaining the same total aperture area measurements as compared to screens composed solely of tall-thick wedge wires, as shown in FIG. 1.

[0062] In some embodiments, each of the short-thin wedge wires 603 is equipped with spacing protrusions 606 spaced along the length of the wedge wire. These spacing protrusions 606 facilitate a secure attachment, whether by a press fit or welded joint, in-between the taller height tall-thick wedge wires 602 and tall-thin wedge wires 601. The incorporation of these spacing protrusions 606 in some embodiments ensures that the precise dimensions of apertures 605 are consistently maintained throughout the structure, thereby optimizing the screening process, as similarly achieved as described in relation to the configuration of FIG. 3, which is applicable to any figure described herein.

[0063] Similar to other non-limiting examples, the supporting rods 604 function as the backbone of the sieve or screen assembly, providing structural integrity and facilitating the attachment of the wedge wires in accordance with some embodiments. The supporting rods 604 may exhibit various cross-sectional profiles, such as polygonal or round, and may be uniform or varied across the assembly to meet specific requirements.

[0064] In some embodiments, the slot 605 formed between adjacent wedge wires dictates the size of particles that can pass through the sieve or screen, ensuring that only particles of a desired size are filtered through the assembly. The arrangement of tall-thick wedge wires 602 with interspersed tall-thin wedge wires 601 and short-thin wedge wires 603, all secured to supporting rods 604, achieves a balance between structural robustness and screening efficiency, consistent with the principles demonstrated in FIG. 2 through FIG. 5.

[0065] Referring further to FIG. 6, a cross-sectional view of a wedge wire screen tube 600 is depicted, which has been cut substantially in half about an axis parallel to the supporting rods 604, according to some embodiments. This cut provides a view of the internal structure and arrangement of the wedge wires 601, 602, 603 and supporting rods 604.

[0066] In some embodiments, supporting rods 604 are positioned on both the first half 607 and second half 608 of the split 609, with two additional supporting rods 604 on each half evenly spaced on the tube. This configuration provides enhanced structural integrity and support to the wedge wires 601, 602, 603.

[0067] The two halves of the wedge wire screen tube 600 are joined at the supporting rods 604 according to some embodiments. Various mechanisms can be employed to achieve this joining. For instance, in some embodiments, mechanical fasteners such as screws, bolts, or rivets are used. This allows for easy assembly and disassembly of the screen tube, facilitating maintenance and replacement procedures. In some embodiments, the joining mechanism could involve welding or adhesive bonding, which provide a more permanent and robust connection between the two halves of the screen tube 600, ensuring a secure and stable structure during operation. The tube can also be separated into more than two sections as desired.

[0068] Regardless of the joining mechanism used, in some embodiments, the two halves of the wedge wire screen tube 600 are configured to align with each other, ensuring a seamless and efficient filtration process. The precise alignment of the halves also contributes to maintaining the desired precise dimension of apertures 605 between the wedge wires 601, 602, 603, optimizing the screening process in accordance with some embodiments.

[0069] It is understood that the system is not limited in its application to the details of construction and the arrangement of components set forth in the previous description or illustrated in the drawings. The system and methods disclosed herein fall within the scope of numerous embodiments. The previous discussion is presented to enable a person skilled in the art to make and use the system according to some embodiments. Any portion of the structures and / or principles included in some embodiments can be applied to any and / or all embodiments: it is understood that features from some embodiments presented herein are combinable with other features according to some other embodiments. Thus, some embodiments of the system are not intended to be limited to what is illustrated but are to be accorded the widest scope consistent with all principles and features disclosed herein.

[0070] Some embodiments of the system are presented with specific values and / or setpoints. These values and setpoints are not intended to be limiting and are merely examples of a higher configuration versus a lower configuration and are intended as an aid for those of ordinary skill to make and use the system.

[0071] Any text in the drawings is part of the system’s disclosure and is understood to be readily incorporable into any description of the metes and bounds of the system. Any functional language in the drawings is a reference to the system being configured to perform the recited function, and structures shown or described in the drawings are to be considered as the system comprising the structures recited therein. It is understood that defining the metes and bounds of the system using a description of images in the drawing does not need a corresponding text description in the written specification to fall with the scope of the disclosure.

[0072] Furthermore, acting as Applicant’s own lexicographer, Applicant imparts the explicit meaning and / or disavow of claim scope to the following terms:

[0073] Applicant defines any use of “and / or” such as, for example, “A and / or B,” or “at least one of A and / or B” to mean element A alone, element B alone, or elements A and B together. In addition, a recitation of “at least one of A, B, and C,” a recitation of “at least one of A, B, or C,” or a recitation of “at least one of A, B, or C or any combination thereof’ are each defined to mean element A alone, element B alone, element C alone, or any combination of elements A, B and C, such as AB, AC, BC, or ABC, for example.

[0074] “Substantially” and “approximately” when used in conjunction with a value encompass a difference of 5% or less of the same unit and / or scale of that being measured (e.g., degrees, volume, mass, distance, percent, etc.).

[0075] The phrase “configured to” denotes the step of configuring a structure to achieve a particular function according to some embodiments. In addition, the term “configured to” means that the limitations recited in the specification and / or the claims must be arranged in such a way to perform the recited function: “configured to” excludes structures in the art that are “capable of’ being modified to perform the recited function but the disclosures associated with the art have no explicit teachings to do so. For example, a recitation of a “container configured to receive a fluid from structure X at an upper portion and deliver fluid from a lower portion to structure Y” is limited to systems where structure X, structure Y, and the container are all disclosed as arranged to perform the recited function. The recitation “configured to” excludes elements that may be “capable of’ performing the recited function simply by virtue of their construction but associated disclosures (or lack thereof) provide no teachings to make such a modification to meet the functional limitations between all structures recited.

[0076] It is understood that the phraseology and terminology used herein is for description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.

[0077] The previous detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict some embodiments and are not intended to limit the scope of embodiments of the system.

[0078] It will be appreciated by those skilled in the art that while the system has been described above in connection with particular embodiments and examples, the system is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications and departures from the embodiments, examples and uses are intended to be encompassed by the claims attached hereto. The entire disclosure of each patent and publication cited herein is incorporated by reference, as if each such patent or publication were individually incorporated by reference herein. Various features and advantages of the system are set forth in the following claims.

Claims

We claim:

1. A wire screen comprising: a plurality of thick wires, a plurality of thin wires, and a plurality of supporting rods; wherein each of the plurality of thin wires are approximately 50% or less of a thickness of each of the plurality of thick wires at a respective base; wherein the plurality of thick wires and the plurality of thin wires are arranged in an alternating configuration; and wherein the plurality of thick wires and the plurality of thin wires are coupled to the plurality of supporting rods in the alternating configuration.

2. The wire screen of claim 1, wherein the wire screen is arranged as a flat panel.

3. The wire screen of claim 1, wherein the wire screen is arranged as a curved panel.

4. The wire screen of claim 1 , wherein the wire screen is arranged as a cylindrical tube.

5. The wire screen of claim 4, wherein the cylindrical tube is separable into a first half and a second half.

6. The wire screen of claim 1, wherein each of the plurality of thin wires are approximately a same length as each of the plurality of thick wires.

7. The wire screen of claim 1, wherein each of the plurality of thick wires includes a wedge profile;wherein a base of each wedge profile is configured to face a flow direction; and wherein the wedge profile narrows from the base to the plurality of supporting rods.

8. The wire screen of claim 7, wherein each of the plurality of thin wires are approximately 50% or less of a length of each of the plurality of thick wires.

9. The wire screen of claim 8, wherein each of the plurality of thin wires are approximately 33% or less of the length of each of the plurality of thick wires.

10. The wire screen of claim 9, wherein each of the plurality of thin wires comprise a different profile than each of the plurality of thick wires.

11. The wire screen of claim 9, wherein each of the plurality of thin wires comprise a wedge profile.

12. The wire screen of claim 1, wherein there are no spacing protrusions between each of the plurality of thick wires and each of the plurality of thin wires.

13. The wire screen of claim 11, further including spacing protrusions between each of the plurality of thick wires and each of the plurality of thin wires.

14. The wire screen of claim 13, wherein each of the spacing protrusions is formed as part of a respective thin wire.

15. The wire screen of claim 13,wherein each of the spacing protrusions are configured to couple a thin wire to an adjacent thick wire.

16. The wire screen of claim 6, further including a plurality of short wires; wherein each of the plurality of short wires are approximately 50% or less a length of the plurality of thick wires and the plurality of thin wires.

17. The wire screen of claim 16, wherein each of the plurality of short wires are approximately the same length.

18. The wire screen of claim 17, wherein each of the plurality of short wires are positioned between a thick wire and a thin wire in the alternating configuration.

19. The wire screen of claim 18, wherein the wire screen is arranged as a hollow cylinder.

20. The wire screen of claim 19, wherein a width of each of the plurality of thick wires, the plurality of thin wires, and the plurality of short wires decrease as each extend toward a centerline of the hollow cylinder.

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