Woven Wire Screen With Varying Weft Coating Thickness
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Solution Overview
Problem
Conventional woven and non-woven wire screens have limited efficiency due to restricted throughput, which affects the classification and processing of materials in shaker or vibrating screen apparatus.
Innovation Solution
The development of woven wire screens with interwoven crimped warp and weft wires, where the weft wires are individually coated with a flexible protective material that expands and contracts, enhancing vibrational movement and tumbling action, and the coating thickness varies to improve performance and throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional woven or non-woven wire screens are used, then the screen structure is simple and easy to manufacture, but the throughput and efficiency are limited
Solution Approach 1:
The screen is divided into multiple layers with different wire configurations. The first screen layer has a first wire pattern while the second screen layer has a second wire pattern, allowing each layer to perform specific functions and collectively increase throughput without excessive complexity in any single layer
Solution Approach 2:
The patent uses composite wire structures where wires are coated with flexible protective material, and the screens combine different wire patterns and materials to create a multi-layer composite structure that improves throughput while maintaining manufacturability
2Productivity
If the open area of the screen is increased to improve throughput, then more material can pass through, but the screen efficiency and classification performance deteriorate
Solution Approach 1:
The screen is segmented into multiple layers with different open area characteristics. The first screen layer can have a different open area percentage than the second screen layer, allowing optimization where each layer contributes to both throughput and classification performance
Solution Approach 2:
Different regions of the multi-layer screen have different local qualities - each wire pattern layer can be optimized for specific classification requirements while maintaining overall high throughput, with the first and second wire patterns providing different local screening characteristics
3Reliability
If wire coatings are applied to protect wires from wear, then wire durability improves, but the tumbling action and vibrational movement of material are reduced
Solution Approach 1:
The coating is applied with varying thicknesses at different locations along the wire. The coating thickness is greater at some locations than at others, providing protection where needed while maintaining tumbling action and vibrational movement in critical areas
Solution Approach 2:
The coating thickness parameter is varied along the wire length. By controlling the coating thickness to be greater at certain locations and less at others, the patent optimizes both wire protection and material tumbling action
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
This design significantly enhances the throughput and efficiency of wire screens by improving the tumbling action and vibrational movement of materials, allowing for greater material flow and classification capabilities compared to conventional screens.
Implementation Method 1
the weft wires are individually coated with a flexible protective material that expands and contracts when objects impact the screening when in use to enhance vibrational movement of the warp wires
Implementation Method 2
an upper screening surface configured to improve the tumbling action of product impacting the upper screening surface to improve the throughput of the wire screening
Data Source
AI summary
A wire screening for classifying material. The screening may include a plurality of interwoven warp and weft wires where the weft wires are individually coated with a coating that expands and collapses to enhance performance and longevity of the screen. The coating of one or more weft wires may differ in at least one characteristic from the coating of one or more other weft wires. The warp wires can be individually coated to enhance performance and/or longevity of the screening. Binding blocks can be used in place of weft wires. The coating of one or more warp wires may differ in at least one characteristic from the coating of one or more other warp wires and/or one or more weft wires. The screening can include a plurality of uncoated weft and warp wires where the crimp depth of each wire forming each opening has a different crimp depth.