Injection Molded Thermoplastic Screening Elements for Vibratory Machines
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Solution Overview
Problem
Conventional screening assemblies for vibratory screening machines face issues such as lack of structural stability and durability, blinding of screening openings, high fabrication complexity, and limited configuration options, particularly with thermoset polymer and metal screens.
Innovation Solution
The use of injection molded thermoplastic materials for screen elements, which are securely attached to subgrid structures to form a screen assembly with varied configurations, providing improved mechanical and chemical properties, including small screening openings and resistance to vibratory loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If thermoset polymer screens are used for fine screening applications, then screening precision is improved, but fabrication complexity increases and manufacturing time is extended
Solution Approach 1:
The screen assembly is divided into multiple individual screen elements that can be manufactured separately using injection molding, then assembled into a complete screen. This segmentation allows each element to be precisely molded with fine openings while simplifying the overall fabrication process compared to molding a large screen as one piece.
Solution Approach 2:
The invention transitions from thermoset polymer materials to thermoplastic materials, changing the fundamental material parameter. This enables the use of injection molding technology which offers simpler, faster, and more precise manufacturing compared to the complex multi-step curing process required for thermoset polymers, while maintaining the ability to create fine screening openings.
2Area of stationary object
If a large single screen is molded to create fine openings, then screening area is increased, but manufacturing reliability decreases due to liquid not reaching all cavities
Solution Approach 1:
Instead of molding one large screen as a single piece, the invention divides the screen into multiple smaller screen elements. Each element can be reliably injection molded with fine openings since the liquid material can easily reach all cavities in smaller molds. These elements are then assembled to form a large screening area, achieving both goals simultaneously.
3Reliability
If thermoset polymer screens are tensioned to secure them to the vibratory machine, then attachment reliability is improved, but screen deformation occurs due to lack of compression resistance
Solution Approach 1:
The invention uses thermoplastic materials that can be molded with integrated reinforcement structures or combined with support frameworks during the molding process. This creates a composite structure that provides both the flexibility needed for secure attachment and the compression resistance to prevent deformation, eliminating the need to choose between attachment reliability and shape stability.
4Duration of action of stationary object
If metal screens are used for wet applications in oil and gas industry, then durability is improved, but fabrication complexity and cost increase
Solution Approach 1:
The invention changes the material parameter from metal to thermoplastic polymers, which can be selected for their chemical resistance and durability in wet environments. This material substitution maintains durability in oil and gas applications while dramatically simplifying fabrication through injection molding, eliminating complex welding, assembly, and finishing operations required for metal screens.
Data Source
AI summary
Screening members, screening assemblies, methods for fabricating screening members and assemblies and methods for screening materials are provided for vibratory screening machines that incorporate the use of injection molded materials. Use of injection molded screen elements provide, inter alia, for: varying screening surface configurations; fast and relatively simple screen assembly fabrication; and a combination of outstanding screen assembly mechanical and electrical properties, including toughness, wear and chemical resistance. Embodiments of the present invention use a thermoplastic injection molded material.