Laminated Vibratory Screen With Thermoplastic Bonding

Solution Overview

Problem

Vibratory separator screens often fail due to loss of structural integrity, loosening of filtering elements, and seal failures, leading to oversized particles passing through, which can result in costly rework and product rejection, especially in wet screening operations.

Innovation Solution

A laminated screen assembly for vibratory separators, comprising a product screen mesh layer and a structural screen mesh layer secured with a thermoplastic polymer, where the structural mesh layer provides rigidity and the thermoplastic layer bonds the two mesh layers together, eliminating the need for additional frames and seals.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional screens are used in vibratory separators, then the structure is simpler and easier to manufacture, but the screen fails due to loss of structural integrity and loosening of filtering elements

Engineering Contradiction:

Improvescreen structural integrityVSAvoidscreen structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The screen is divided into two distinct layers: a structural mesh layer providing rigidity and support, and a filtering mesh layer performing the separation function. This segmentation allows each layer to be optimized for its specific function, with the structural layer preventing failure and the filtering layer maintaining screening efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses a composite structure combining two different mesh layers with different wire diameters and functions. The structural mesh layer with larger diameter wires provides mechanical strength, while the filtering mesh layer with smaller diameter wires provides separation capability. This composite approach resolves the contradiction by integrating both structural integrity and filtering function into a single unified screen assembly.

Inventive Principle:

Principle #40Composite materials

2Reliability

If additional frames and seals are used to prevent screen failure, then the screening reliability improves, but the device complexity and manufacturing cost increase

Engineering Contradiction:

Improvescreening operation reliabilityVSAvoidscreen manufacturing simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The structural mesh layer and filtering mesh layer are bonded together to form an integrated laminated screen assembly that functions as a complete screening unit. This merging eliminates the need for separate frames, seals, and tensioning mechanisms, as the laminated structure itself provides the necessary structural support and containment for reliable operation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The laminated screen structure is self-supporting and self-contained, with the structural mesh layer providing inherent rigidity and the bonded construction eliminating the need for external sealing compounds or tensioning components. The screen assembly serves its own structural and sealing functions, reducing manufacturing complexity.

Inventive Principle:

Principle #25Self-service

3Manufacturing precision

If the product screen mesh layer uses finer wires for better filtering, then the screening precision improves, but the structural integrity decreases

Engineering Contradiction:

Improvescreening mesh precisionVSAvoidscreen structural strength

Core Design Contradiction:

Manufacturing precisionVSStrength

Solution Approach 1:

The screen is divided into two distinct layers: a structural mesh layer providing rigidity and support, and a filtering mesh layer performing the separation function. This segmentation allows each layer to be optimized for its specific function, with the structural layer preventing failure and the filtering layer maintaining screening efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses a composite structure combining two different mesh layers with different wire diameters and functions. The structural mesh layer with larger diameter wires provides mechanical strength, while the filtering mesh layer with smaller diameter wires provides separation capability. This composite approach resolves the contradiction by integrating both structural integrity and filtering function into a single unified screen assembly.

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The laminated screen design enhances structural integrity, reduces the risk of screen failure, and allows for easier installation and maintenance, while eliminating the need for costly sealing compounds and tensioning components, thereby improving operational efficiency and reducing costs.

Implementation Method 1

a thermoplastic polymer, wherein the structural screen mesh layer is configured to provide structural integrity to the laminate screen

Methodology Applied

Scientific EffectThermoplastic bonding:

Data Source

PatentUS9415420B2Laminated screens

Publication Date: 2016.08.16 M I LLC(US)

AI summary

A laminate screen for a vibratory separator, the screen including a product screen mesh layer having a plurality of wires. The screen further including a structural screen mesh layer having a plurality of wires secured to the product screen mesh layer with a thermoplastic polymer, wherein the structural screen mesh layer is configured to provide structural integrity to the laminate screen, and wherein a diameter of the product screen mesh layer wires is less than a diameter of the structural screen mesh layer wires.