Screening assembly, kit, and method for shale shaker
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- FULL CIRCLE ENERGY LLC
- Filing Date
- 2026-01-30
- Publication Date
- 2026-08-06
Smart Images
Figure US2026013225_06082026_PF_FP_ABST
Abstract
Description
Atty. Dkt. No.: 292-0003US-1- SCREENING ASSEMBLY, KIT, AND METHOD FOR SHALE SHAKERCROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Appl. No. 63 / 752,167 filed January 31 , 2025, which is incorporated herein by reference in its entirety.BACKGROUND OF THE DISCLOSURE
[0002] Shale shakers are used in oil field operations, such as drilling operations. The shale shaker separates solid particles, such as drill cuttings, from drilling fluid so the drilling fluid can be reused. During drilling, the drilling fluid lubricates the drill bit, stabilizes the wellbore, and carries cuttings to the surface. Without effective solids control, the drilling fluid would quickly become overloaded with cuttings, reducing its efficiency and potentially causing operational issues like clogging or damage to downstream equipment.
[0003] The shale shaker uses a vibrating screen system to separate drilling fluid from the slurry coming from the wellbore. The drilling fluid laden with solids is fed onto the shaker’s mesh screens, which are vibrated by an electric motor or other mechanical system. The vibration creates a linear or elliptical motion that propels the slurry across the screen surface. Any solid particles larger than the screen’s mesh size are retained on the screen and discharged as waste, while cleaned fluid (and any smaller particles) pass through the screen for recirculation. The shaker’s design, including screen size and vibration intensity, can be adjusted to suit specific drilling conditions and optimize separation efficiency.
[0004] The vibratory shakers use replaceable screens, which become clogged and damaged over time and need to be repeatedly replaced. The replaceable screens can have flat or corrugated screening surface and are held on a bed of the shaker’s basket, which is vibrated. Several arrangements have been used to hold the replaceable screens in place.
[0005] In a common arrangement, brackets and wedges are used to hold flat screens against a flat surface of a shaker’s bed. Because the flat screens have a planar screen area, material can build up at the edges of the screen, which can eventually cause maintenance and contamination problems.
[0006] A tensioning arrangement, such as disclosed in U.S. Pat. No. 6,669,027 uses attachment hooks that grip the sides of the screen and pull it into an upwardly bowed or convex shape above the shaker’s bed.
[0007] A compressive arrangement, such as disclosed in U.S. Pat. Nos. 7,578,394; 8,443,984; 9,027,760; 9,056,335; 9,956,592; and 11,890,647, uses pins that can extendAtty. Dkt. No.: 292-0003US-2-from the basket’s sidewall to press against the edges of a flat screen panel, causing the screen panel to compress inward against a concave surface of the basket’s bed. The resulting concave shape is therefore created by laying a flexible flat screen in the basket and mechanically pushing pins through the basket’s sidewalls into contact with edges of the screen panel to compress the screen in a concave shape on the basket’s bed.Mechanical levers, pneumatic or hydraulic mechanisms, or other actuators mounted on the outside of the basket’s sidewall can be operated to push the pins inward into the basket to engage the screen panels.
[0008] Due to the demanding environment in which the replaceable screens are used, the replaceable screens suffer from wear and tear from abrasive particles, chemical exposure, temperatures effects, and high-frequency vibrations. Fine particles can eventually clog the screens, blinding the screen openings and lowering the screen’s efficiency. Moreover, any misalignment or loose installation of the screen panels due to improper installation or tensioning can allow the screen panels to shift during operation, leading to inefficient separation and damage to the screen. Misalignment also increases the risk of fluid bypassing the screen entirely.
[0009] Although current vibratory shakers and replaceable screen arrangements may be effective, operators are continually seeking ways to reduce the amount of downtime required to replace screens, to reduce the costs involved with such systems, and to reduce the effects of one or more of the problems set forth above.BRIEF DESCRIPTION OF DRAWINGS
[0010] Fig. 1A illustrates a perspective view of a vibratory shaker having a screening assembly according to the present disclosure.
[0011] Fig. 1B illustrates partial end views of a sidewall of a shaker’s basket with fixtures according to the present disclosure.
[0012] Fig. 1C illustrates partial side views of the sidewall of the shaker’s basket with the disclosed fixtures.
[0013] Fig. 2A illustrates a schematic end view, showing fixtures of the disclosed assembly assembled in a basket of the vibratory shaker and showing a screen panel of the disclosed assembly ready to be positioned in the basket.
[0014] Fig. 2B illustrates a schematic end view of the screen panel initially placed in the basket of the vibratory shaker.
[0015] Fig. 2C illustrates a schematic end view of the screen panel flexed on the bed of the vibratory shaker.Atty. Dkt. No.: 292-0003US-3-
[0016] Fig. 2D illustrates a schematic end view of the screen panel held in the vibratory shaker by the fixture of the disclosed assembly.
[0017] Fig. 3A illustrates a plan view of a bottom of the first example screen panel.
[0018] Fig. 3B illustrates a plan view of a top of a first example of a screen panel according to the present disclosure.
[0019] Fig. 4A illustrates a perspective view at a longitudinal edge of the first example screen panel.
[0020] Fig. 4B illustrates a detail of a lateral edge of the first example screen panel.
[0021] Fig. 4C illustrates an end view of end bars for the first example screen panel.
[0022] Figs. 5A-5B illustrate perspective views of the first example screen panel placed in the basket of a vibratory shaker.
[0023] Fig. 5C illustrates a side plate for the disclosed screening assembly.
[0024] Fig. 5D illustrates a side wedge for the disclosed screening assembly.
[0025] Fig. 6A illustrates a plan view of a bottom of a second example of a screen panel according to the present disclosure.
[0026] Fig. 6B illustrates a plan view of a top of the second example screen panel.
[0027] Fig. 7 illustrates a plan view the second example screen panel held in the basket of a vibratory shaker.
[0028] Figs. 8A, 8B and 8C schematically illustrate a process for assembling a screen panel according to the present disclosure.
[0029] Fig. 9 illustrates the process for assembling the screen panel in flow chart form.DETAILED DESCRIPTION OF THE DISCLOSURE
[0030] Fig. 1A illustrates a perspective view of a vibratory shaker 10 having a screening assembly 30 according to the present disclosure. The screening assembly 30 can be a kit used to retrofit a vibratory shaker 10, or a vibratory shaker 10 can be manufactured with features of the disclosed screening assembly 30. The screening assembly 30 and the vibratory shaker 10 work together to separate solids from a slurry (such as drilling slurry) so drilling fluid can be reused.
[0031] In general, the vibratory shaker 10 has a discharge chute or basket 20 with a back and a front for passage of slurry. A hopper or feeder 26 can deliver the slurry (such as drilling fluid and cuttings) to screen panels 40 to screen the slurry. The basket 20 has a curved bed 24 extending laterally between vertical sidewalls 22a-b, and the curved bed 24 defines a concave curvature.
[0032] A vibration mechanism, such as electric motors 28 and eccentric weights, mounted on the basket 20 vibrates the basket 20 to move the slurry across the screenAtty. Dkt. No.: 292-0003US-4-panels 40 for effective separation of the liquid (drilling fluid) and solids (cuttings, etc.). Typically, the basket 20 is supported in a deck and other supporting structures, which are not shown, and vibration dampeners, such as rubber pads or springs, can support the basket 20 on the deck to minimize vibrations transferred to the surrounding structure.
[0033] The screen panels 40 line the bed 24 of the basket 20, and the screen panels 40 have a screening material, such as mesh, for the separation of solids and fluids. The mesh screening material can be configured for particle size separation for an implementation at hand. Although not visible in Fig. 1 , the bed 24 of the basket 40 has a plurality of rails or ribs extending laterally between the sidewalls 22a-b. These rails are spaced from one another for passage of fluid from the basket 20 through the bed. To improve engagement of the screen panels 40 with the rails of the bed 24, elastomer seals in the form of strips can be mounted on the rails so the screen panels 40 can seal against the elastomer seals.
[0034] Beneath the screen panels 40 and the bed 24, a mud collection pan (not shown) can collect the filtered drilling fluid (or mud) for recirculation. Meanwhile, the front of the basket 20 allows separated solids (cuttings) to be discharged from the vibratory shaker 10. As described in more detail below, a screen tensioning system 60 having fixtures, including shoulders 74 (e.g., a tab, a lip, a ledge, or the like), wedges 80, and other elements, ensures the screen panels 40 remain in place and that the screening material of the screen panels 40 remains taut during operation. In one configuration, the screen tensioning system 60 can be arranged on one of the sidewalls (e.g., 22b shown in Fig. 1 A) of the basket 20, while the other sidewall 22a can include a shoulder (74) (e.g., a tab, a lip, a ledge, or the like) that can be located close to the bed 24 so one edge of each screen panel 40 can fit between the shoulder (74) on the sidewall 22a and the bed 24 without the need for wedges 80. Furthermore, in another configuration, the screen tensioning system 60 can be arranged on both of the sidewalls 22a-b of the basket 20 to engage both edges of the screen panel 40 with the wedges 80. (For the sake of explanation, the shoulders 74 are referred to herein as tabs 74, although other structures can be used based on the teachings of the present disclosure.)
[0035] Fixtures of the screen tensioning system 60 can be arranged in various configurations. For example, Fig. 1B illustrates partial end views of a sidewall 22 of a shaker’s basket with fixtures according to the present disclosure, and Fig. 1C illustrates partial side views of the sidewall 22 of the shaker’s basket with the disclosed fixtures.
[0036] In one configuration, tabs 74 are attached to the inside surface of the sidewall by welding, bolting, or the like. Shown here, bolts 75 are used through the sidewall 22 to affixAtty. Dkt. No.: 292-0003US-5-the tabs 74. The tabs 74 are arranged at an angle relative to an axial direction (A) of the basket, which has cross bars or rails 25 defining the curved bed 24. The tabs 74 can include lips 76 on the ends to create a pocket for a wedge (80).
[0037] In another configuration, tabs 74 are attached (welded) to an angled edge 72 of a side plate 70, which is attached to the sidewall 22 by welding, bolting, or the like. Shown here, bolts 75 are used through the sidewall 22 to affix the side plate 70. The tabs 74 are arranged at an angle relative to an axial direction (A) of the basket, which has cross bars or rails 25 defining the curved bed 24. The tabs 74 here are planar.
[0038] In yet another configuration, tabs 74 are attached (welded) to an angled edge 72 of a side plate 70, which is attached to the sidewall 22 by welding, bolting, or the like. Shown here, bolts 75 are used through the sidewall 22 to affix the side plate 70. The tabs 74 are arranged at an angle relative to an axial direction (A) of the basket, which has cross bars or rails 25 defining the curved bed 24. The tabs 74 here have lips 76.
[0039] Features of the screening assembly 30 and the basket 20 are shown in more detail in Figs. 2A-2D. In particular, Fig. 2A illustrates a schematic end view, showing fixtures of the screen tensioning system 60 assembled in the basket 20 of the vibratory shaker and showing a screen panel 40 ready to be positioned in the basket 20.
[0040] Side tabs 74 extend from the sidewalls 22a-b inward to the basket 20. Each of the tabs 74 is angled with respect to an axial direction (A) (through the page) between the front and back of the basket 20 so wedges 80 can be wedged under the side tabs 74. In one configuration, the side tabs 74 can be individually affixed to the sidewalls 22a-b of the basket 20, such as using bolts, welding, or the like. In another configuration, a bracket having a side plate can include the side tabs 74 affixed to an upper edge (by welding or the like) of the side plate, and the side plate can be affixed to the sidewalls 22a-b of the basket 20 (by using bolts, welding, or the like). (Bolting from outside the sidewalls 22a-b for the side plates is depicted in Fig. 1.)
[0041] As shown in Fig. 2A, the screen panel 40 has a bottom 42, a top 44, and opposing ends 46a-b. These ends 46a-b are longitudinal edges 46a-b that will run along the axial direction of the basket’s sidewalls 22a-b when the screen panel 40 is positioned in the basket 20. The screen panel 40 is flexible, but is fabricated to have a predefined concave curvature in a lateral (or cross) direction (L) between the opposing ends 46a-b. The predefined concave curvature has an initial predefined radius R1 , which is a smaller radius than the radius R0 for the concave curvature of the basket’s bed 24.
[0042] Fig. 2B illustrates a schematic end view of the screen panel 40 initially placed in the basket 20 of the vibratory shaker. Because the screen panel 40 has a smallerAtty. Dkt. No.: 292-0003US-6-curvature radius R1 , the center of the screen panel 40 can contact the curved bed 24. Once the screen panel 40 is positioned on the basket’s bed 24, however, the screen panel 40 can be flexed to a flexed concave curvature in which the panel’s bottom 42 is disposed adjacent to curved bed 24, as shown in Fig. 2C. The opposing ends 46a-b are flexed downward between the side tabs 74 and the bed 24.
[0043] With the screen panel 40 flexed on the curved bed 24 of the shaker’s basket 20, the screen panel 40 has a flexed concave curvature with a radius R2 that is greater than the panel’s predefined radius R1 for its initial concave curvature. When flexed, for example, the radius R2 of the panel's concave curvature can be increased to reach the existing radius R0 of the basket’s curved bed 24.
[0044] As then shown in Fig. 2D, the screen panel 40 is then held in the shaker’s basket 20 by fixtures of the screen tensioning system 60. In particular, operators wedge the side wedges 80 between the tabs 74 and the edges 46a-b of the flexed screen panel 40 to hold the screen panel 40 in place. As noted, because the initial concave curvature (i.e., the initial radius R1 ) of the screen panel 40 is smaller than the radius R0 of the shaker bed 24, the screen panel 40 is pressed into place by the wedges 80 driven against the edges 46a-b of the screen panel 40. Accordingly, the wedges 80 impart a radial force on the screen panel 40 (i.e., in the direction of curvature), putting the screening material in tension. This directed force pushes the screen panel 40 against the elastomer seals in the basket bed 24. The directed force can therefore provide a tighter seal on the screen panel 40 to reduce bypass of mud around the screen panel 40.
[0045] In the current configuration, both sidewalls 22a-b include the features of the screen tensioning system (60), namely the wedges 80 and the side plates 70 with affixed tabs 74. Other configurations for the tabs 74, such as in Figs. 1 B-1 C, can be used.Additionally, as noted previously, features of the screen tensioning system (60) can be arranged on one of the sidewalls (e.g., 22b) of the basket 20, while the other sidewall (e.g., 22a) can include tabs 74 (e.g., a shoulder, a lip, a ledge, or the like) that can be located close to the bed 24 so one edge (e.g., 46a) of each screen panel 40 can fit between the tabs 74 on the sidewall 22a and the bed 24 without the need for wedges 80. This configuration is shown in an end detail A and a side detail B of Fig. 2D. For example, a side plate 70 with tabs 74 can be disposed on the sidewall 22a so that the tabs 74 are located close to the bed 24 defined by the rails 25. One edge 46a of each screen panel 40 can engage in the space between the tabs 74 on the sidewall 22a and the bed 24 without the need for wedges 80. The other edges 46b of the screen panels 40 would be engaged with the wedges 80 as before. This will still allow the screen panels 40 to flex to a flexedAtty. Dkt. No.: 292-0003US-7-concave curvature in the basket 20 so the screen panels 40 in the flexed concave curvature have bottoms disposed adjacent the curved bed 24.
[0046] Features of the screen panel 40 are discussed with reference to Figs. 3A through 4C. Fig. 3A illustrates a plan view of a bottom of a first example of a screen panel 40. The bottom 42 of the screen panel 40 has a frame 54 having a flexible material. For example, the frame 54 can be composed of a sheet of metal, such as aluminum, steel, or other metal, or the frame 54 can be composed of plastic or other suitable material. When the screen panel 40 is flexed to the flexed concave curvature, the curvature of the frame 54 can mate with the curvature of the basket’s bed (24).
[0047] Fig. 3B illustrates a plan view of a top of the first example screen panel 40. The top of the screen panel 40 has a screening material affixed to the frame 54. For example, the screening material 50 can be adhered with an adhesive to the frame 54. The adhesive chosen needs to be an appropriate industrial adhesive or epoxy to withstand the operational conditions. The screening material 50 can be composed of a suitable material for a given implementation and can use metal mesh or the like. Depending on the materials used, other forms of attachment can be used to affix the screening material 50 to the frame 54, including, for example, spot welding, riveting, clamping, bolting, or the like.
[0048] Fig. 4A illustrates a perspective view at a longitudinal edge 48 of the first example screen panel 40, and Fig. 4B illustrates a detail of an edge 46b of the first example screen panel 40. As shown in this example, the screening material 50 can define a plurality of corrugations 52 extending in a direction across the longitudinal edges 48 of the screen panel 40. Troughs of the corrugations 52 are attached to the frame 54, and crests of the corrugations 52 are spaced from the frame 54. Any open ends of the corrugations 52 along the longitudinal edges 58 can be filled with adhesive or otherwise plugged to avoid bypass. When the screen panel 40 is flexed to the flexed concave curvature, the screening material 50 may tend to stretch in tension in the lateral direction (L).
[0049] As shown, the screen panel 40 can have edge bars 56a-b affixed on the top of the screen panel 40 along the lateral edges 46a-b. The edge bars 56a-b can be adhered with the adhesive over ends of the screening material 50 on the frame 54. As before, depending on the materials used, other forms of attachment can be used to affix the edge bars 56a-b, including, for example, spot welding, riveting, clamping, bolting, or the like.
[0050] Fig. 4C illustrates an end view of end bars 56a-b for the first example screen panel 40. The edge bars 56a-b can define a wedged cross-section so the top of the edge bars 56a-b can be engaged with a bottom edge of a wedge (80).Atty. Dkt. No.: 292-0003US-8-
[0051] Figs. 5A-5B illustrate perspective views of the first example screen panel 40 placed in the basket 20 of a vibratory shaker. For the screen tensioning system 60, a side plate 70 having affixed tabs 74 along an angled edge is shown against a sidewall 22 of the basket. The position of the edge bars 56a-b on the screen panel 40 is shown placed between the tabs 74 and the basket’s bed 24.
[0052] Fig. 5C illustrates an elevational view of a side plate 70 for the screen tensioning system 60. As noted, the side plate 70 includes an angled edge 72 that is angled relative to the bottom edge 73. One or more tabs 74 are disposed on the angled edge 72. Bolt holes 75’ can be provided for affixing the side plate 70 to a sidewall (22) of a basket (20).
[0053] To facilitate manufacture and assembly, the tabs 74 can mounted on the angled edge 72 of the side plates 70, which fit against the inside surface of the sidewalls (22). For example, the side plates 70 can have outer sides 71b that are placed against the inner surface of the sidewalls (22) and can be affixed with bolts or other fasteners through bolt holes 75’. The side plate’s top edge 72 can be angled with respect to the axial direction between the front and the back of the basket (20) when mounted to the sidewall (22). The top edge 72 can have at least one side tab 74 extending from the side plate’s inner side 71a. For example, the side plate 70 shown in Fig. 5C has two side tabs 74 on the top edge 72, although only one side tab 74 may be used.
[0054] The end bars (56) of the screen panel 40 can fit between the side plates 70 bolted to the sidewalls (22), and the wedges 80 can be wedged between the tabs 74 and the screen panel’s end bars (56) to push the screen panel 40 into its final shape against the basket’s curved bed (24).
[0055] Fig. 5D illustrates an elevational view of a side wedge 80 for the screen tensioning system 60. Comparable to the side plate 70, the side wedge 80 includes an angled edge 82 that is angled relative to the bottom edge 83. The angled edge 82 allows the side wedge 80 to be wedged under the tabs 74 on the side plate 70 to the side wedge’s bottom edge 83 can press against the end bars (56) on the screen panel (40). When the screen panel 40 is held in place, the end bars (56) and the bottom (42) of the screen panel (40) at the opposing ends (46) are sandwiched between the side wedges 80 and the inner edges of basket’s bed (24).
[0056] Fig. 6A illustrates a plan view of a bottom of a second example of a screen panel 40 according to the present disclosure, and Fig. 6B illustrates a plan view of a top of the second example screen panel 40. Fig. 7 illustrates a plan view of the second example screen panel 40 held in the basket 20 of a vibratory shaker. The opposing ends 46a-b of the screen panel 40 can define one or more slots 47. The end bars 56a-b disposed on theAtty. Dkt. No.: 292-0003US-9-top of the screen’s ends 46a-b have comparable slots 47. When the screen panel 40 is placed on the curved bed 24, the one or more slots 47 allow the ends 46a-b and end bars 56a-b to fit past the one or more side tabs 74 extending from the sidewalls 22a-b.
[0057] As shown in Fig. 7, the bed 24 typically has cross bars or rails 25 on which elongated seals, such as rubber strips, are positioned. The bottom 42 of the screen panels 40 fit against these seals on the rails 25 when the screen panels 40 are held in place on the bed 24.
[0058] Figs. 8A, 8B and 8C schematically illustrate a process 100 for assembling a screen panel 40 according to the present disclosure, and Fig. 9 illustrates the process 100 in flowchart form. The frame 54 of flexible material is formed to have a predefine concave curvature (Block 120). The frame 54 of the screen panel 40 can be punched, stamped, or laser / water cut. The frame 54 can then be rolled through pinch rollers to impart a permanent concavity that is much more concave than the mating surface on the seals on the curved bed 24 of the basket 20.
[0059] The screening material 50 can then be bonded to the frame 54. In particular, adhesive can be applied to surfaces of the frame 54. Combinations of one or more corrugated mesh for the screening material 50 can be bonded with the adhesive to the frame’s surface. Removable spacers 110 are interposed between the screening material 50 and the frame 54 (Block 124), and the frame 54, removable spacers 110, and the screening material 50 are positioned between bonding fixtures 102, 106 (Block 126). The bonding fixtures 102, 106 can be pressed together (Block 128).
[0060] Because the frame 54 already defines a concave curvature, the frame 54 can be supported in a concavity 104 of the bonding fixture 102, and the other bonding fixture 106 with a convexity 108 can press the mesh screening material 50 against the supported frame 54. Features on the convexity 108 and the removable spacers 110 can be used to produce the corrugations 52.
[0061] The edge bars 56a-b are bonded and / or mechanically attached to the ends of the screen panel 40 (Block 130). As noted, these edge bars 56a-b provide a horizontal mating surface for the wedges (80) to thoroughly press the screen panel 40 into the seals on the basket’s concave bed (24).
[0062] Configurations of the present disclosure can be characterized by the following clauses:Clause 1. An assembly for use in a vibratory shaker (10), the vibratory shaker (10) having a basket (20) with a back and a front for passage of slurry, the basket (20)Atty. Dkt. No.: 292-0003US-10-having a curved bed (24) extending laterally between sidewalls (22a-b), the curved bed (24) defining a concave curvature (Ro), the assembly comprising:side shoulders (74), each of the side shoulders (74) being configured to extend from a respective one of the sidewalls (22a-b) inward to the basket (20), at least one of the side shoulders (74) on at least one of the sidewalls (22a-b) being angled with respect to a direction between the front and the back of the basket (20);a screen (40) having a top, a bottom, and opposing ends (46a-b), the screen (40) being flexible and having a predefined concave curvature (Ri) in a lateral direction between the opposing ends (46a-b), the predefined concave curvature (Ri) having a smaller radius than the concave curvature (Ro) of the bed (24), the screen (40) being configured to position in the basket (20) and being flexible to a flexed concave curvature (R2), the screen (40) in the flexed concave curvature (R2) having the bottom disposed adjacent the bed (24) and having the opposing ends (46a-b) disposed between the side shoulders (74) and the bed (24), the flexed concave curvature (R2) having a greater radius than the predefined concave curvature (Ri); andside wedges (80), each having an upper edge and a bottom edge, each of the upper edges being angled with respect to the bottom edge, each of the side wedges (80) being configured to wedge between the at least one side shoulder (74) on at least one of the sidewalls (22a-b) and the respective opposing end (46a-b) of the screen (40), the side wedges (80) being configured to hold the screen (40) in the flexed concave curvature (R2) against the bed (24).Clause 2. A kit to retrofit a vibratory shaker (10), the vibratory shaker (10) having a basket (20) with a back and a front for passage of slurry, the basket (20) having a curved bed (24) extending laterally between sidewalls (22a-b), the curved bed (24) defining a concave curvature (Ro), the kit comprising:side shoulders (74), each of the side shoulders (74) being configured to affix to a respective one of the sidewalls (22a-b) and extending inward to the basket (20), at least one of the side shoulder on at least one of the sidewalls being angled with respect to a direction between the front and the back of the basket (20);screens (40), each of the screens (40) having a top, a bottom, and opposing ends (46a-b), each of the screens (40) being flexible and having a predefined concave curvature in a lateral direction between the opposing ends (46a-b), the predefined concave curvature (Ri) having a smaller radius than the concave curvature (Ro) of the bed (24), each of the screens (40) being configured to position in the basket (20) and being flexible to a flexed concave curvature (R2), the screen (40) in the flexed concave curvature (R2) having theAtty. Dkt. No.: 292-0003US-11-bottom disposed adjacent the bed (24) and having the opposing ends (46a-b) disposed between the side shoulders (74) and the bed (24), the flexed concave curvature (R2) having a greater radius than the predefined concave curvature (R1 ); andside wedges (80), each of the side wedges (80) having an upper edge and a bottom edge, each of the upper edges being angled with respect to the bottom edge, each of the side wedges (80) being configured to wedge between the at least one side shoulder (74) on the at least one sidewall (22a-b) and the respective opposing end (46a-b) of the screens (40), the side wedges (80) being configured hold the screens (40) in the flexed contact curvature (R2) against the bed (24).Clause 3. A system, comprising:a vibratory shaker (10) having a basket (20) with a back and a front for passage of slurry, the basket (20) having a curved bed (24) extending laterally between sidewalls (22a-b), the curved bed (24) defining a concave curvature (Ro) and being opened for passage of liquid from the slurry;side shoulders (74), each of the side shoulders (74) extending from a respective one of the sidewalls (22a-b) inward to the basket (20), at least one of the side shoulders (74) on at least one of the sidewalls (22a-b) being angled with respect to a direction between the front and the back of the basket (20);screens (40), each of the screens (40) having a top, a bottom, and opposing ends (46a-b), each of the screens (40) being flexible and having a predefined concave curvature (R1) in a lateral direction between the opposing ends (46a-b), the predefined concave curvature having a smaller radius than the concave curvature (Ro) of the bed (24), the screens (40) being positioned in the basket (20) and being flexed to a flexed concave curvature (R2), the screens (40) in the flexed concave curvature (Ro) having the bottom disposed adjacent the bed (24) and having the opposing ends (46a-b) disposed between the side shoulders (74) and the bed (24), the flexed concave curvature (R2) having a greater radius than the predefined concave curvature (R1 ); andside wedges (80), each of the side wedges (80) having an upper edge and a bottom edge, each of the upper edges being angled with respect to the bottom edge, each of the side wedges (80) being configured to wedge between the at least one side shoulder (74) on the at least one sidewall (22a-b) and the respective opposing end (46a-b) of the screen (40), the side wedges (80) holding the screens (40) in the flexed concave curvature (R2) against the bed (24).Clause 4. A method of installing a screen (40) in a vibratory shaker (10), the vibratory shaker (10) having a basket (20) with a back and a front for passage of slurry, theAtty. Dkt. No.: 292-0003US-12-basket (20) having a curved bed (24) extending laterally between sidewalls (22a-b), the curved bed (24) defining a concave curvature (Ro), the method comprising:placing a flexible screen (40) in the basket (20), the screen (40) having a predefined concave curvature (Ri) in a lateral direction between opposing ends (46a-b) of the screen (40), the predefined concave curvature (Ri) having a smaller radius than the concave curvature (Ri) of the bed (24);flexing the flexible screen (40) to a flexed concave curvature (R2) in the basket (20), the screen (40) in the flexed concave curvature (R2) having a bottom of the screen (40) disposed adjacent the bed (24), the flexed concave curvature (R2) having a greater radius than the predefined concave curvature (Ri ); andengaging the opposing ends of the screen between side shoulders on the sidewalls and the curved bed by wedging at least one of the respective opposing ends (46a-b) of the screen (40) against the bed (24).Clause 5. The method of Clause 4, wherein wedging the at least one respective opposing end (46a-b) of the screen (40) against the bed (24) comprises inserting a side wedge (80) between the respective opposing end (46a-b) of each screen (40) and the side shoulder (74) disposed on the at least one sidewall (22a-b) of the basket (20), each of the side wedges (80) having an upper edge and a bottom edge, each of the upper edges being angled with respect to the bottom edge, each of the side wedges (80) being configured to wedge between the side shoulder (74) and the respective opposing end of the screen (40).Clause 6. The method of Clause 5, wherein flexing the flexible screen (40) to the flexed concave curvature (R2) in the basket (20) comprises fitting a slot on each of the opposing ends (46a-b) of the screen (40) past one of the side shoulders (74) extending from the sidewall.Clause 7. The method of Clause 4, 5 or 6, wherein flexing the flexible screen (40) to the flexed concave curvature (R2) in the basket (20) comprises stretching a screening material (50) in tension in the lateral direction of the screen (40).Clause 8. A method of assembling a screen (40) for use in a vibratory shaker (10), the method comprising:forming a frame (54) for the screen (40) by configuring a flexible material of the frame (54) with a predefined concave curvature (Ro) in a lateral direction (L) between opposing ends (46a-b) of the frame (54); andattaching a screening material (50) to a surface of the frame (54) in the predefined concave curvature (Ri) by configuring the screening material (50) to stretch in tension inAtty. Dkt. No.: 292-0003US-13-the lateral direction (L) of the screen (40) in response to flexing of the screen (40) to a flexed concave curvature (R2) with a greater radius than the predefined concave curvature (R1).Clause 9. The method of claim 8, wherein attaching the screening material (50) to the surface of the frame (54) in the predefined concave curvature (R1) comprises attaching the screening material (50) with adhesive to the surface of the frame (54).Clause 10. The method of claim 8 or 9, wherein attaching the screening material (50) to the surface of the frame (54) in the predefined concave curvature (R1) comprises:forming the screening material (50) with corrugations (52) in a longitudinal direction; andattaching toughs of the corrugations (52) to the surface of the frame (54) with crests of the corrugations (52) spaced from the surface of the frame (54) and extending in the longitudinal direction across the frame (54).Clause 11. The method of claim 10, forming the screening material (50) and attaching the screening material (50) comprises:interposing removable spacers (110) between the frame (54) and the screening material (50);positioning the frame (54), the removable spacers (110), and the screening material (50) between a first bonding fixture (102) having a concavity (104) and a second bonding fixture (106) having a convexity (108); andpressing the first bonding fixture (102) and the second bonding fixture (106) together.Clause 12. The method of any one of Clauses 8 to 11 , further comprising attaching bars (56a-b) in a longitudinal direction on opposing edges of the frame (54).Clause 13. The assembly, kit, and method of any preceding Clause, comprising side plates (70), each of the side plates (70) having a top edge (72), an outer side (71b), and an inner side (71a), each of the outer sides (71b) being configured to position against a respective one of the sidewalls (22a-b), each of the inner sides (71a) facing inward to the basket (20), each of the top edges (72) being angled with respect to the direction between the front and the back of the basket (20), each of the top edges (72) having at least one side tab (74) for the side shoulder extending from the inner side (71a).Clause 14. The assembly, kit, and method of Clause 13, wherein each of the side plates (70) has more than one of the side tabs (74) on the top edge (72).Clause 15. The assembly, kit, and method of any preceding Clause, wherein the bottom of the screen (40) comprises a frame (54) having a flexible material; wherein theAtty. Dkt. No.: 292-0003US-14-top of the screen (40) comprises a screening material (50) affixed to the frame (54); and wherein the screen (40) flexed to the flexed concave curvature (Ro) stretches the screening material (50) in tension in the lateral direction (L).Clause 16. The assembly, kit, and method of Clause 14, wherein the screening material (50) defines a plurality of corrugations (52) extending in a longitudinal direction across the screen (40).Clause 17. The assembly, kit, and method of Clause 16, wherein troughs of the corrugations (52) are attached to the frame (54); and wherein crests of the corrugations (52) are spaced from the frame (54).Clause 18. The assembly, kit, and method of Clause 16 or 17, wherein the screening material (50) is adhered with an adhesive to the frame (54).Clause 19. The assembly, kit, and method of any preceding Clause, wherein the screen (40) comprises edge bars (56a-b) affixed on the top of the screen (40) along the opposing ends (46a-b), the edge bars (56a-b) defining a wedged cross-section; and wherein the edge bar (56a-b) and the bottom of the screen (40) at the respective opposing end (46a-b) is sandwiched between the side wedge (80) and the bed (24) of the basket (20).Clause 20. The assembly, kit, and method of any preceding Clause, wherein each of the opposing ends (46a-b) of the screen (40) defines a slot (47) configured to fit past one of the side shoulders (74) extending from the sidewall.
[0063] The foregoing description of preferred and other embodiments is not intended to limit or restrict the scope or applicability of the inventive concepts conceived of by the Applicants. It will be appreciated with the benefit of the present disclosure that features described above in accordance with any embodiment or aspect of the disclosed subject matter can be utilized, either alone or in combination, with any other described feature, in any other embodiment or aspect of the disclosed subject matter.
[0064] In exchange for disclosing the inventive concepts contained herein, the Applicants desire all patent rights afforded by the appended claims. Therefore, it is intended that the appended claims include all modifications and alterations to the full extent that they come within the scope of the following claims or the equivalents thereof.
Claims
Atty. Dkt. No.: 292-0003US-15- CLAIMS:
1. An assembly for use in a vibratory shaker, the vibratory shaker having a basket with a back and a front for passage of slurry, the basket having a curved bed extending laterally between sidewalls, the curved bed defining a concave curvature, the assembly comprising:side shoulders, each of the side shoulders being configured to extend from a respective one of the sidewalls inward to the basket, at least one of the side shoulders on at least one of the sidewalls being angled with respect to a direction between the front and the back of the basket;a screen having a top, a bottom, and opposing ends, the screen being flexible and having a predefined concave curvature in a lateral direction between the opposing ends, the predefined concave curvature having a smaller radius than the concave curvature of the curved bed, the screen being configured to position in the basket and being flexible to a flexed concave curvature, the screen in the flexed concave curvature having the bottom disposed adjacent the curved bed and having the opposing ends disposed between the side shoulders and the curved bed, the flexed concave curvature having a greater radius than the predefined concave curvature; andside wedges, each having an upper edge and a bottom edge, the upper edge being angled with respect to the bottom edge, each of the side wedges being configured to wedge between the at least one side shoulder on the at least one sidewall and the respective opposing end of the screen, the side wedges being configured to hold the screen in the flexed concave curvature against the curved bed.
2. The assembly of claim 1 , comprising side plates, each of the side plates having a top edge, an outer side, and an inner side, the outer side being configured to position against a respective one of the sidewalls, the inner side facing inward to the basket, the top edge being angled with respect to the direction between the front and the back of the basket, the top edge having at least one side tab for the side shoulder extending from the inner side.
3. The assembly of claim 2, wherein each of the side plates has more than one of the at least one side tab on the top edge.Atty. Dkt. No.: 292-0003US-16-4. The assembly of claim 1 , wherein the bottom of the screen comprises a frame having a flexible material; wherein the top of the screen comprises a screening material affixed to the frame; and wherein the screen flexed to the flexed concave curvature stretches the screening material in tension in the lateral direction.
5. The assembly of claim 4, wherein the screening material defines a plurality of corrugations extending in a longitudinal direction across the screen.
6. The assembly of claim 5, wherein troughs of the corrugations are attached to the frame; and wherein crests of the corrugations are spaced from the frame.
7. The assembly of claim 5, wherein the screening material is adhered with an adhesive to the frame.
8. The assembly of claim 1 , wherein the screen comprises edge bars affixed on the top of the screen along the opposing ends, the edge bars defining a wedged cross-section; and wherein the edge bar and the bottom of the screen at the respective opposing end is sandwiched between the side wedge and the curved bed of the basket.
9. The assembly of claim 1 , wherein each of the opposing ends of the screen defines a slot configured to fit past one of the side shoulders extending from the sidewall.
10. A kit to retrofit a vibratory shaker, the vibratory shaker having a basket with a back and a front for passage of slurry, the basket having a curved bed extending laterally between sidewalls, the curved bed defining a concave curvature, the kit comprising:side shoulders, each of the side shoulders being configured to affix to a respective one of the sidewalls and extending inward to the basket, at least one of the side shoulders on at least one of the sidewalls being angled with respect to a direction between the front and the back of the basket;screens, each of the screens having a top, a bottom, and opposing ends, each of the screens being flexible and having a predefined concave curvature in a lateral direction between the opposing ends, the predefined concave curvature having a smaller radius than the concave curvature of the curved bed, each of the screens being configured to position in the basket and beingAtty. Dkt. No.: 292-0003US-17- flexible to a flexed concave curvature, the screens in the flexed concave curvature having the bottom disposed adjacent the curved bed and having the opposing ends disposed between the side shoulders and the curved bed, the flexed concave curvature having a greater radius than the predefined concave curvature; andside wedges, each of the side wedges having an upper edge and a bottom edge, the upper edge being angled with respect to the bottom edge, each of the side wedges being configured to wedge between the at least one side shoulder on the at least one sidewall and the respective opposing end of the screens, the side wedges being configured hold the screens in the flexed concave curvature against the curved bed.
11. The kit of claim 10, comprising side plates, each of the side plates having a top edge, an outer side, and an inner side, the outer side being configured to position against a respective one of the sidewalls, the inner side facing inward to the basket, the top edge being angled with respect to the direction between the front and the back of the basket, the top edge having at least one side tab for the side shoulder extending from the inner side.
12. The kit of claim 11 , wherein each of the side plates has more than one of the at least one side tab on the top edge.
13. The kit of claim 10, wherein the bottom of the screen comprises a frame having a flexible material; wherein the top of the screen comprises a screening material affixed to the frame; and wherein the screen flexed to the flexed concave curvature stretches the screening material in tension in the lateral direction.
14. The kit of claim 13, wherein the screening material defines a plurality of corrugations extending in a longitudinal direction across the screen.
15. The kit of claim 14, wherein troughs of the corrugations are attached to the frame; and wherein crests of the corrugations are spaced from the frame.
16. The kit of claim 14, wherein the screening material is adhered with an adhesive to the frame.Atty. Dkt. No.: 292-0003US-18- 17. The kit of claim 10, wherein the screen comprises edge bars affixed on the top of the screen along the opposing ends, the edge bars defining a wedged cross-section; and wherein the edge bar and the bottom of the screen at the respective opposing end is sandwiched between the side wedges and the curved bed of the basket.
18. The kit of claim 10, wherein each of the opposing ends of the screen defines a slot configured to fit past one of the side shoulders extending from the sidewall.
19. A system, comprising:a vibratory shaker having a basket with a back and a front for passage of slurry, the basket having a curved bed extending laterally between sidewalls, the curved bed defining a concave curvature and being opened for passage of liquid from the slurry;side shoulders, each of the side shoulders extending from a respective one of the sidewalls inward to the basket, at least one of the side shoulders on at least one of the sidewalls being angled with respect to a direction between the front and the back of the basket;screens, each of the screens having a top, a bottom, and opposing ends, each of the screens being flexible and having a predefined concave curvature in a lateral direction between the opposing ends, the predefined concave curvature having a smaller radius than the concave curvature of the curved bed, the screens being positioned in the basket and being flexed to a flexed concave curvature, the screens in the flexed concave curvature having the bottom disposed adjacent the curved bed and having the opposing ends disposed between the side shoulders and the curved bed, the flexed concave curvature having a greater radius than the predefined concave curvature; andside wedges, each of the side wedges having an upper edge and a bottom edge, the upper edge being angled with respect to the bottom edge, each of the side wedges being configured to wedge between the at least one side shoulder on the at least one sidewall and the respective opposing end of the screen, the side wedges holding the screens in the flexed concave curvature against the curved bed.Atty. Dkt. No.: 292-0003US-19- 20. A method of installing a screen in a vibratory shaker, the vibratory shaker having a basket with a back and a front for passage of slurry, the basket having a curved bed extending laterally between sidewalls, the curved bed defining a concave curvature, the method comprising:placing a flexible screen in the basket, the screen having a predefined concave curvature in a lateral direction between opposing ends of the screen, the predefined concave curvature having a smaller radius than the concave curvature of the curved bed;flexing the flexible screen to a flexed concave curvature in the basket, the screen in the flexed concave curvature having a bottom of the screen disposed adjacent the curved bed, the flexed concave curvature having a greater radius than the predefined concave curvature; andengaging the opposing ends of the screen between side shoulders on the sidewalls and the curved bed by wedging at least one of the respective opposing ends of the screen against the curved bed.
21. The method of claim 20, wherein wedging the at least one respective opposing end of the screen against the curved bed comprises inserting a side wedge between the respective opposing end of each screen and the side shoulder disposed on the at least one sidewall of the basket, each of the side wedges having an upper edge and a bottom edge, the upper edge being angled with respect to the bottom edge, each of the side wedges being configured to wedge between the side shoulder and the respective opposing end of the screen.
22. The method of claim 21 , wherein flexing the flexible screen to the flexed concave curvature in the basket comprises fitting a slot on each of the opposing ends of the screen past one of the side shoulder extending from the sidewall.
23. The method of claim 20, wherein flexing the flexible screen to the flexed concave curvature in the basket comprises stretching a screening material in tension in the lateral direction of the screen.
24. A method of assembling a screen for use in a vibratory shaker, the method comprising:Atty. Dkt. No.: 292-0003US-20- forming a frame for the screen by configuring a flexible material of the frame with a predefined concave curvature in a lateral direction between opposing ends of the frame; andattaching a screening material to a surface of the frame in the predefined concave curvature by configuring the screening material to stretch in tension in the lateral direction of the screen in response to flexing of the screen to a flexed concave curvature with a greater radius than the predefined concave curvature.
25. The method of claim 24, wherein attaching the screening material to the surface of the frame in the predefined concave curvature comprises attaching the screening material with adhesive to the surface of the frame.
26. The method of claim 24, wherein attaching the screening material to the surface of the frame in the predefined concave curvature comprises:forming the screening material with corrugations in a longitudinal direction; and attaching toughs of the corrugations to the surface of the frame with crests of the corrugations spaced from the surface of the frame and extending in the longitudinal direction across the frame.
27. The method of claim 26, forming the screening material and attaching the screening material comprises:interposing removable spacers between the frame and the screening material; positioning the frame, the removable spacers, and the screening material between a first bonding fixture having a concavity and a second bonding fixture having a convexity; andpressing the first bonding fixture and the second bonding fixture together.
28. The method of claim 24, further comprising attaching bars in a longitudinal direction on opposing edges of the frame.