Abstract:
An apparatus has a frame with a screen portion and a discharge portion adjacent thereto. The frame has a bottom surface and a substantially planar top surface. The top surface extends from the screen portion to the discharge portion. An opening located in the screen portion of the frame extends through the frame from the top surface to the bottom surface. A spout formed in the discharge portion has a shape of a hollow cylinder and extends through the frame from the top surface to the bottom surface. A system has a separator with an inlet into which material to be separated enters. A unitary screen frame has a screen portion and a discharge spout with a planar top surface extending from the screen portion to the discharge spout. A first portion of the material entering the inlet flows from the planar top surface to the discharge spout.

Description:
BACKGROUND 
     In certain industries and/or applications, separating one material from a second material is often desired and/or required. Further, the separation of solids based upon the relative size of the solids is generally known in a variety of industries and/or applications. Typically, separation by size is performed for various reasons. For example, separation of a like material by size may be desired to categorize the material into different sizes. Certain sizes may be more valuable or desirable. Thus, separating and/or categorizing the material by size may optimize the value of the material for a subsequent sale of the separated material. Further, certain food products are separated by size for grading purposes. Certain sizes of a particular food product may be more valuable or desirable. 
     To this end, separators may be used to separate different materials and/or to separate like materials by size. Typically, separators may use screens having different mesh sizes. The screens may be arranged relative to one another to allow the smaller material that may pass through a top screen to flow onto the screen below so that the materials may be separated. A series of stacked screens may be used in the separator. Also, the separator may use vibration and/or other motion to aid in the separation process. 
     Conventional vibratory separators generally utilize screens of either hook strip or pretensioned design. The screens may be tensioned after the screens have been mounted in the basket of the vibratory screen apparatus. Two opposed ends of the screen are fitted with a turn back element to form a hook strip. The hook strip may be hooked around a tension rail which may be attached to the side wall of the basket. Typically, a tension bolt may be used. However, other loading means to apply tensioning and securing forces may be employed. Tightening the tension bolt may move the tension rail outwardly towards the walls of the basket to apply tension to the screen. 
     Hook strip screens may be pretensioned prior to mounting in the basket by attachment of the screen mesh element to an apertured support plate, typically by means of an adhesive. A screen having a plurality of mesh layers may be pretensioned. In some designs, layers of fused mesh may be corrugated prior to mounting to an apertured support plate and the hooks applied thereafter to the mesh-plate combination. 
     Hook strip screens have a number of disadvantages including the complex and time consuming mounting of the screen members in the basket which results in significant downtime of the vibratory screen apparatus and requires the use of multiple parts. Attaining the correct screen tension for the sieved material also involves intricate fine tuning. The screens may be easily damaged if too much force is applied when tightening the bolts or loading means to tension the screens. 
     A further disadvantage is the relatively poor sealing between the screen and the basket. The metal-on-metal seal often results in leakage. Unscreened material may pass through gaps between the screen and the basket and may mix with already screened material below the mesh screen. Attempts to overcome the poor seal by placing rubber strips and/or gaskets at the metal/metal interfaces are time-consuming. The strips and/or gaskets frequently loosen during vibration and become lost or lodged in the vibratory machine which obstructs and/or damages the machinery. In addition, applying tension to the screen when tightening the tension bolt adds undesirable stresses to the machine frame. 
     Pretensioned screens generally have one or more layers of mesh permanently bonded under tension onto a generally rigid steel and/or plastics material apertured plate support frame. The screen and frame are inserted into the basket and are normally secured in the machine by clamps. 
     Conventional pretensioned screen units with integral support frames have significant disadvantages. For example, conventional pretensioned screens may be bulky, heavy and difficult to handle, transport and store. Typically, the design may be complex, and the frames may be expensive to construct. 
     Further, the material and/or the product may build up and may be trapped between the spacing frame and other parts of the separator as the material and/or the product may be separated. Therefore, the machine must be taken apart for cleaning which may create a non-productive, labor-intensive step. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a prior art screen frame and a separate spout for use in a separator. 
         FIG. 2  illustrates a cutaway side view of a separator having an integrated screen frame in accordance with embodiments disclosed herein. 
         FIG. 3  illustrates a cutaway perspective view of the separator having the integrated screen frame in accordance with embodiments disclosed herein. 
         FIG. 4  illustrates a cutaway perspective view of the separator having the integrated screen frame in accordance with embodiments disclosed herein. 
         FIG. 5  illustrates a perspective view of the integrated screen frame in accordance with embodiments disclosed herein. 
         FIG. 6  illustrates a top view of the integrated screen frame in accordance with embodiments disclosed herein. 
     
    
    
     DETAILED DESCRIPTION 
     The embodiments disclosed herein relate generally to an apparatus and a system for separating materials. More specifically, embodiments disclosed herein relate to a unitary screen frame and discharge spout apparatus and system. 
     Screens may be used to filter particles in industrial filtration systems. For example, industrial separators may use screens to separate particles and/or material of different sizes. To promote separation, vibrational and/or circular motion may be applied to the screen. 
       FIG. 1  illustrates a prior art screen frame  10  for use in a separator (not shown). The separator may be one of various types of separators, such as an industrial separator, a vibratory separator, a shaker and/or the like, for example. Generally, the screen frame  10  may have a single layer of mesh  11 . Multiple layers of mesh may also be bonded together. The mesh  11  may be tensioned after mounting the screen frame  10  in the separator. Typically, the screen frame is metal. The screen frames  10  that may be used in separators are usually constructed of stainless steel. The manufacture of the screen frame  10  may require laser cutting, forming and/or welding. 
     The separator may have a spacing frame  12  that may connect to the screen frame  10 . The screen frame  10  may be secured in the separator by using a hook strip mechanism. As shown in  FIG. 1 , the screen frame  10  may have a lip  13  that may extend from the outer periphery of the screen frame  10 . The spacing frame  12  may have a flange  14  located an end  15  of the spacing frame  12 . The lip  13  of the screen frame  10  may have a gasket  16  connected thereto. The flange  14  of the spacing frame  12  may be positioned against the gasket  16 . A retaining clamp  17  may encompass the flange  14  of the spacing frame  12  and the gasket  16  connected to the lip  13  of the screen frame  12 . The retaining clamp  17  may be tightened in a conventional manner to secure the screen frame  10  to the spacing frame  12 . 
     As shown in  FIG. 1 , a gap  18  may be formed between the outer periphery of the screen frame  10  and the end  15  of the spacing frame  12 . In use, material and/or product may be trapped in the gap and/or in other crevices that may be present within the separator. As a result, the material and/or the product may not pass through the separator and may not exit the separator through a discharge spout  19  formed in the spacing frame  12 . 
     The material and/or the product may build up and/or may become trapped between the spacing frame and the screen frame as the material and/or the product passes over the screen frame  10 . Since the material and/or product may remain in the separator, the separator may be taken apart for cleaning to avoid cross-contamination. As a result, the user may be required to perform a non-productive step and/or a labor-intensive step. Also, if such material and/or product may remain in the separator, the ability to run different products without cleanup between batches may be lost. 
     Referring to  FIGS. 2-6 , an integrated screen frame  100  in accordance with embodiments disclosed herein is illustrated. The integrated screen frame  100  may have a screen portion  101  and a discharge portion  102  integrally formed with the screen portion  101 . The integrated screen frame  100  may have a top surface  103  that may be substantially planar. The top surface  103  may extend from the screen portion  101  to the discharge portion  102 . Thus, the screen portion  101  and the discharge portion  102  may be integrally formed and may be substantially co-planar. The discharge portion  102  may have a discharge spout  104 . 
     The integrated screen frame  100  may have a screen  105 . The screen  105  may have a single layer of woven mesh wire or may be multiple layers of woven mesh wire. The screen  105  may be a mesh cloth. The screen  105  may have a mesh size to filter particles. For example, the screen  105  may have the mesh size to separate like material and/or different material into various categories based upon the size of the particles. The mesh size as used herein may refer to the size of the apertures in the screen  105 . The screen  105  may be circular as shown in  FIGS. 2-6 . However, other shapes may be used as desired. The screen  105  may be arranged over an opening  106 . The screen  105  may be attached to the top surface  103  of the screen portion  101  of the integrated screen frame  100 . The screen may be embedded and/or molded to the screen portion  101  of the integrated screen frame  100 . 
       FIGS. 2-4  illustrate the integrated screen frame  100  mounted in a separator  110 . For simplicity, the upper portion of the separator  110  is shown. In the illustrated embodiment, the separator  110  may have a generally circular shape. However, other shapes may be used, as desired. The shape of the integrated screen frame  100  may be coordinated to the shape of the separator  110  that may be used. In an embodiment, the separator  110  and the integrated screen frame  100  may be constructed from high performance injection molded composite plastics. An additive may be in the high performance injection molded composite plastics to make the separator  110  and the integrated screen frame  100  static dissipating. The separator  110  and the integrated screen frame  100  may feature internal geometry that may be smooth and/or gap free. Such gap free geometry may be preferred in applications, such as the food industry and/or the pharmaceutical industry, for example. Contamination may be reduced with such gap free geometry. Further, the gap free geometry may allow the ability to run different products without cleanup between batches due to the low levels of cross contamination that may occur in such a smooth, gap free environment. 
     As shown in  FIGS. 2-4 , the separator  110  may have a lid  111 . The lid  111  may be generally circular in shape. The lid  111  may have an inlet  112  to provide a supply of material and/or product to the separator  110  for separation. The inlet  112  may be located approximately in the center of the lid  111 . However, the inlet  112  may be positioned at other locations as desired. The separator  110  may also have a spacing frame  115 . 
     The spacing frame  115  may have a body  116  defined by a wall  117 . The body  116  may be generally circular in shape. The lid  111  which may also be circular may be attached to the body  116 . The lid  111  may fit on the wall  117 . The lid  111  and the body  116  of the spacing frame  115  may be secured together. 
     As shown in  FIG. 2 , the spacing frame  115  may also have an extended portion  119  that may extend outwardly from the body  116 . The extended portion  119  may have an end  120  with a through hole  121  formed therein. The through hole  121  may be configured to receive a securing mechanism  122  as shown in  FIGS. 3 and 4 . The securing mechanism  122  may have a shaft  123  which may pass through the through hole  121 . The securing mechanism  122  may also have a lever  124 . Operation of the securing mechanism  122  may be described hereinafter. 
     As illustrated in  FIGS. 2-6 , the integrated screen frame  100  may have an upper recess  125  that may be formed in the periphery thereof. The upper recess  125  may be configured to receive the wall  117  of the body  116  of the spacing frame  115 . The extended portion  119  of the spacing frame  115  may also have a wall  127 . Further, the upper recess  125  may receive the wall  127  of the extended portion  119  of the spacing frame  115 . The wall  117  of the body  116  of the spacing frame  115  and the wall  127  of the extended portion  119  may contact the upper recess  125  of the integrated screen frame  100 . Thus, the upper recess  125  may form a seal with the spacing frame  115  around the complete periphery. 
     The integrated screen frame  100  may have a tab  129  that may be located at the outer periphery of the discharge portion  102 . The tab  129  may have a notch  130  formed therein. The notch  130  may receive the shaft  123  of the securing mechanism  122 . To operate the securing mechanism  122 , the lever  124  may be moved to rotate the shaft  123  within the through hole  121  in the end  120  of the extended portion  119  of the spacing frame  115 . The lever  124  may also be moved to rotate the shaft  123  within the notch  130  of the discharge portion  102  of the integrated screen frame  100 . The securing mechanism  122  may be used to tighten the spacing frame  115  onto the upper recess  125  of the integrated screen frame  100 . Rotating the lever  124  may draw together the spacing frame  115  and the integrated screen frame  100  to further tighten the seal formed between the upper recess  125  and the spacing frame  115 . 
     The separator  110  may have a table frame  135  that may have a wall  136 . The wall  136  may have a top edge  137  and a bottom edge  138 . The integrated screen frame  100  may be located on the table frame  135 . In particular, the integrated screen frame  100  may have a lower recess  139  that may be formed in a bottom surface  140  of the screen portion  101 . 
     The table frame  135  may have an opening  141  in the wall  136 . The opening  141  may provide a conduit to a discharge port  143 . The table frame  135  may also have a shelf  144  that may be attached to the wall  136  and may be located between the top edge  137  and the bottom edge  138  of the wall  136  as shown in  FIGS. 3 and 4 . 
     In a separation operation in accordance with the embodiments disclosed herein, material and/or product  150  may enter the separator  110  through the inlet  112  in the lid  111 . The material and/or the product  150  may contact the screen  105  on the integral screen frame  100  as shown in  FIG. 2 . The motion of the separator  110  may produce a spiraling of the material and/or the product  150 . An operator of the separator  110  may make adjustments to parameters, such as weight settings, vibration, speeds, flows and/or the like to control the performance of the separator  110  for the desired separation of the material and/or the product  150 . 
     The screen  105  may have the mesh size to filter particles of the desired size of the material and/or the product  150 . For example, the screen  105  may have the mesh size to separate like materials and/or different materials into various categories based upon the size of the particles. The mesh size as used herein may refer to the size of the apertures in the screen  105 . Particles of larger size than the mesh size may not pass through the screen  105  on the integral screen frame  100  during the separation operation. Such larger particles may be moved from the screen portion  101  to the discharge portion  102  of the integral screen frame  100 . The larger particles may move toward the discharge portion  102  and may pass through the discharge spout  104 . The screen portion  101  and the discharge portion  102  of the integral screen frame  100  may be integrally formed and may be substantially co-planar. The larger particles may pass without interruption through the discharge spout  104  without becoming trapped in gaps and/or crevices. Thus, the interior of the separator  110  may provide smooth, gap free surfaces for processing and/or separating the material and/or the product  150 , as desired. The interior of the separator  110  may also be static dissipating. 
     In operation, particles of the material and/or the product  150  of a smaller size than the mesh size may pass through the screen  105  on the integral screen frame  100  during the separation operation. The material and/or the product  150  that may pass through the screen  105  may accumulate below the screen  105  on the shelf  144  within the wall  136  of the table frame  135 . Operation of the separator  110  may transport the material and/or the product  150  from the shelf  144  through the opening  141  to the discharge port  143 . 
     In the separation operation, particles of the larger size than the mesh size may not pass through the screen  105  on the integral screen frame  100  during the separation operation. Such larger particles may be moved from the screen portion  101  to the discharge portion  102  of the integral screen frame  100 . The larger particles may move toward the discharge portion  102  and may pass through the discharge spout  104 . The larger particles may be collected at the discharge spout  104  for further processing and/or packaging. 
     Also, the particles of the material and/or the product  150  of a smaller size than the mesh size may pass through the screen  105  on the integral screen frame  100  during the separation operation. The material and/or the product  150  that may pass through the screen  105  may accumulate below the screen  105  on the shelf  144  within the wall  136  of the table frame  135 . Operation of the separator  110  may transport the material and/or the product  150  from the shelf  144  through the opening  141  to the discharge port  143 . The smaller particles may be collected at the discharge port  143  for further processing and/or packaging. 
     While the present disclosure has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments may be devised which do not depart from the scope of the disclosure as described herein. Accordingly, the scope of the present disclosure should be limited only by the attached claims.