Patent Publication Number: US-10758942-B2

Title: Clip and seal assembly

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present document is based on and claims priority to U.S. Provisional Application Ser. No. 62/218,535, filed Sep. 14, 2015, which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND 
     Vibratory separators are used to separate solid particulates of different sizes and/or to separate solid particulate from fluids. Various industries use vibratory separators for filtering materials, for example, the oil and gas industry, the food processing industry, the pharmaceutical industry, and the agriculture industry. A vibratory separator is a vibrating sieve-like table upon which solids-laden fluid is deposited and through which clean fluid emerges. The vibratory separator may be a table with a generally perforated filter screen bottom. Fluid is deposited at the feed end of the vibratory separator. As the fluid travels down the length of the vibrating table, the fluid falls through the perforations to a reservoir below, leaving the solid particulate material behind. The vibrating action of the vibratory separator table conveys solid particles left behind to a discharge end of the separator table. 
     The vibratory shaker includes a screen disposed within a basket of the vibratory separator. The screens themselves may be flat or nearly flat, corrugated, depressed, or contain raised surfaces. Due to the vibration or shaking of the vibratory separator, and the materials processed through the vibratory separator, the screens, as well as other parts, in the separator may wear over time. Therefore, screens are removably secured in the basket so they can be removed for repair or replacement. 
     The above described apparatus is illustrative of one type of shaker or vibratory separator known to those of ordinary skill in the art. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  shows a perspective view of a screen frame with a plurality of screen inserts installed in accordance with one or more embodiments of the present disclosure. 
         FIG. 2  shows a top view of a portion of a screen frame with a plurality of screen inserts installed in accordance with one or more embodiments of the present disclosure. 
         FIG. 3 , taken along lines  3 - 3  of  FIG. 2 , shows a cross-sectional side view from a longitudinal side of a portion of a screen frame with a screen insert installed in accordance with one or more embodiments of the present disclosure. 
         FIG. 4 , taken along lines  4 - 4  of  FIG. 2 , shows a cross-sectional side view from a transverse side of a portion of a screen frame with a screen insert installed in accordance with one or more embodiments of the present disclosure. 
         FIG. 5  shows a top perspective view of a portion of a screen frame in accordance with one or more embodiments of the present disclosure. 
         FIG. 6  shows side perspective view of a screen insert prior to installation in a section of a screen frame in accordance with one or more embodiments of the present disclosure. 
         FIG. 7  shows a perspective view of a section of a screen frame with a screen insert installed in accordance with one or more embodiments of the present disclosure. 
         FIG. 8  shows a cross-sectional view of a portion of a screen frame with a screen insert installed in accordance with one or more embodiments of the present disclosure. 
         FIG. 9  shows a top view of a portion of a screen frame with a plurality of screen inserts installed in accordance with one or more embodiments of the present disclosure. 
         FIG. 10 , taken along lines  7 - 7  of  FIG. 1 , shows a cross-sectional side view from a transverse side of a screen frame with a plurality of screen inserts installed in accordance with one or more embodiments of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The following is directed to various examples of embodiments of the disclosure. The embodiments disclosed should not be interpreted, or otherwise used, as limiting the scope of the disclosure, including the claims. In addition, those having ordinary skill in the art will appreciate that the following description has broad application, and the discussion of any embodiment is meant only to be an example of that embodiment, and not intended to suggest that the scope of the disclosure, including the claims, is limited to that embodiment. Specifically, while embodiments disclosed herein may reference shale shakers or vibratory separators used to separate cuttings from drilling fluids in oil and gas applications, one of ordinary skill in the art will appreciate that a vibratory separator (or vibratory shaker) and its component parts as disclosed herein and methods disclosed herein may be used in any industrial application. For example, vibratory separators in accordance with embodiments disclosed herein may be used in the food industry, cleaning industry, waste water treatment, and others. 
     Certain terms are used throughout the following description and the claims refer to particular features or components. As those having ordinary skill in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name but not function. The figures are not necessarily to scale. Certain features and components herein may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in interest of clarity and conciseness. 
     In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . .” Also, the term “couple” or “couples” is intended to mean either an indirect or direct connection. Thus, if a first component is coupled to a second component, that connection may be through a direct connection, or through an indirect connection via other components, devices, and connections. Additionally, directional terms, such as “above,” “below,” “upper,” “lower,” etc., are used for convenience in referring to the accompanying drawings. 
     Embodiments disclosed herein relate generally to vibratory separators, and in particular, to vibratory separators having one or more high capacity screen assemblies. High capacity screen assemblies may be used to increase or maximize the amount of fluid capacity of a vibratory separator (e.g., the number of gallons per minute of drilling fluid or mud that a vibratory separator can process). The higher fluid capacity a vibratory separator has, the fewer separators and screens may be used to maintain drilling operations. High capacity sifting or filtering screens are designed to maximize the flow rate of drilling fluids which may be processed and include an assembly of parts which involve additional manufacturing and assembly processes. 
     High capacity screen assemblies may include, for example, a modified single screen that provides higher effective processing capacity than a standard or conventional single screen. For example, a high capacity screen assembly may include a screen frame having a first screening surface disposed above a second screening surface. In other words, a single screen frame includes a two-tier screening surface. The two-tier screening surface may be integrally formed with the screen frame or one or both of the two tiers of the screening surface may be coupled to the screen frame. In some embodiments, the first screening surface may be coupled to the second screening surface or may be coupled to the screen frame. 
     In some embodiments, a high capacity screening assembly may include one or more screen inserts installed into a screen frame. For example, a screen frame may include a screen surface having a plurality of openings, and a screen insert disposed in a first opening of the plurality of openings of the screen frame. A single screen frame or deck having two screening surfaces (i.e., two-tier screening surface), may provide a larger screening surface area than the screening surface area of the screen frame alone and/or may provide double screening of a material within a single screen frame when the two screening surfaces of the single screen frame are positioned in series so that fluid passes through two screening surface of the screen frame. Examples of two-tier screening assemblies are shown and described in WO 2013/188322, assigned to the assignee of the present application, and incorporated by reference in its entirety. 
     Embodiments of the present disclosure provide a screen frame with a mating or sealing surface configured to engage a screen insert inserted into an opening of the screen frame. Embodiments of the present disclosure also provide a screen insert with a mating or sealing surface configured to engage one or more longitudinal or transverse ribs of a screen frame when the screen insert is inserted in an opening of the screen frame. The mating and/or sealing surfaces of the screen frame and/or screen insert may be configured to reduce or prevent leaks between the screen insert and the screen frame in accordance with embodiments disclosed herein. 
     The mating face may be provided between the screen frame and the insert. In some embodiments, a gasket may be installed to provide a seal between the insert and the screen frame. To alleviate the need for a gasket to provide a satisfactory seal, the mating face may be moved from a top mesh surface of the screen frame to a lower sealing surface of the screen frame. The mating face may taper to a point which creates a convoluted path, making it likely that solids that find the path will pack out and create a filter cake, blocking unwanted particles from passing through. 
     To increase the flow rate of wellbore fluid through a screen frame, a screen frame insert is inserted into an opening of the screen frame. The screen frame insert increases the surface area of the screen frame, by providing another screening surface for the wellbore fluid. The openings of the screen are formed by the intersection of a plurality of longitudinal ribs and a plurality of transverse ribs. In some embodiments, a mating surface may be located on a longitudinal rib or may be located on a transverse rib. In other embodiments, the mating surface may be located on both longitudinal ribs and both transverse ribs, thus surrounding the opening. The mating surface may be located on any combination of a longitudinal rib and/or a transverse rib, such as could be designed by one of ordinary skill in the art. 
     In some embodiments, the screen frame insert may also include a plurality of openings formed by the intersection of a plurality of longitudinal ribs and a plurality of transverse ribs. In some embodiments, a sealing surface may be located on a longitudinal rib or may be located on a transverse rib. In other embodiments, the sealing surface may be located on both longitudinal ribs and both transverse ribs, thus surrounding the opening. The sealing surface may be located on any combination of a longitudinal rib and/or a transverse rib, such as could be designed by one of ordinary skill in the art. In some embodiments, the sealing surface of the screen frame insert corresponds to the mating surface of the screen frame. In some embodiments, the sealing surface of the screen frame insert corresponds to the mating surface of the screen frame. 
     By having mating surfaces and sealing surfaces which correspond, insertion of the screen frame insert into the screen frame may be assisted. The corresponding mating surfaces and sealing surfaces may also aid in blocking unwanted particles passing through. After inserting the screen frame insert into the opening of the screen frame and aligning the corresponding mating surfaces and sealing surfaces, a tortuous path makes it likely that any solids finding the path would create a filter cake. To ensure the screen frame insert is “seated” onto the screen frame, force may be applied, such that the corresponding mating surfaces and sealing surfaces form a seal. 
     In yet other embodiments, the screen frame insert may include an extending member which may engage with at least one of the longitudinal ribs and/or the transverse ribs of the screen frame. In some embodiments, the screen frame insert may engage the screen frame via one or more clips located on the extending member. In other embodiments, the longitudinal ribs and/or the transverse ribs of the screen frame may include a plurality of teeth which engage with the extending member of the screen frame insert. Embodiments of the screen frame and screen frame insert are described below. 
     Referring to  FIGS. 1-3 , a perspective view, a top view, and a cross-sectional side view of an example of a high capacity screen assembly in accordance with embodiments of the present disclosure are shown, respectively. In this embodiment, a screen frame  100  having a plurality of screen insert units  101  disposed therein is shown. The screen frame  100  is configured to be installed in a vibratory separator frame (not shown) as will be understood by one of ordinary skill in the art. The screen frame  100  may be a composite screen frame; however, one of ordinary skill in the art will appreciate that other types of screen frames may be used without departing from the scope of embodiments disclosed herein. The screen frame  100  is formed having a plurality of transverse ribs  107  and a plurality of longitudinal ribs  109  defining a plurality of openings  105 . 
     In some embodiments, the screen insert unit  101  may include a plurality of longitudinal ribs  104  and one or more transverse ribs  106  defining individual sections of the screen insert unit  101 . A screen insert unit  101  may have a single section, two sections, three sections, four sections, or more, depending on the application the screen insert. The longitudinal and transverse ribs  104 ,  106  of the screen insert unit  101  may provide structural stability to the screen insert unit  101  and/or to a screen mesh disposed on top of the screen insert unit  101 . A top surface of the screen insert unit  101  may have a rectangular surface area. The top surface area of the screen insert unit  101  may be based on the shape of the screen frame  100 . A screen insert unit  101  may have a single lower portion or insert portion  150 , two lower portions or insert portions, three lower portions or insert portions, four lower portions or insert portions, or more, depending on the application of the screen insert unit  101 . In certain embodiments, and as shown in the figures, a lower portion  150  of the screen insert unit  101  may be generally square-shaped or rectangular-shaped to fit within a generally rectangular or square opening  105  of the screen frame  100 . In other embodiments, the lower portion  150  of the screen insert unit  101  may have a cross-sectional shape which corresponds with the cross-sectional shape of the opening  105  in the screen frame  100 , including but not limited to circular, oval, triangular, and other known shapes. The screen insert units  101  may be inserted in one or more openings  105  of the screen frame, such that the screen insert unit  101  extends upward from a top surface of the screen frame  100  to provide an additional screening surface. Thus, each screen insert unit  101  includes an insert portion or lower portion  150  and a screening portion or upper portion  140 . In some embodiments, the screen insert unit  101  will have a plurality of insert portions or lower portions  150  corresponding to a number of openings  105  of the screen frame  100 . For example, in one embodiment, as shown in  FIG. 1 , the screen insert unit  101  may have four insert portions or lower portions  150  to be inserted into four corresponding openings  105 . In another embodiment, as shown in  FIG. 9 , the screen insert unit  101  may have three insert portions or lower portions  150  to be inserted into three corresponding openings  105 . In other embodiments, any number of insert portions or lower portions  150  may be included in the screen insert unit  101 , such as for example, two, four, or more. The number of insert portions or lower portions  150  in a modular screen insert unit may depend on, for example, the size of the screen  100 , the number of openings  105 , and/or a desired screening area for a particular screen. 
     In some embodiments, the shape and size of each of the openings  105  defined by the plurality of transverse ribs  107  and longitudinal ribs  109  may be the same. In other embodiments, the shape and size of each of the openings  105  may vary. For example, in some embodiments, one or more openings  105   a  may be configured such that the shape and size of the opening  105   a  corresponds to a configuration (e.g., shape and size) of an insert portion  150  of a screen insert unit  101 . One or more other openings  105   b  of the screen frame may have a configuration different from the openings  105   a  configured to receive an insert portion  150  of a modular screen insert unit  101 . In this embodiment, the one or more other openings  105   b  may be configured to allow material to pass from an upper surface to a bottom surface of the screen  100  during processing of a material, but may not be configured to receive a modular screen insert unit  101 . Various configurations of openings  105   a  configured to receive a modular screen insert unit  101  are discussed in more detail below. 
     As shown in  FIG. 1 , for example, a screen frame  100  in accordance with some embodiments of the present disclosure includes a first row of openings  105   a  configured to receive one or more screen insert units  101  and second row of openings  105   c  configured to receive one or more screen insert units  101 , with one or more rows of openings  105   b  configured to allow material to pass from an upper surface to a bottom surface, but without modular screen insert units  101  inserted therein. One of ordinary skill in the art will appreciate that various configurations of openings  105  configured to receive a screen insert unit and openings configured to allow material to pass therethrough without a screen insert unit disposed therein may be used without departing from the scope of embodiments herein. For example, a screen frame  100  may include three rows of screen insert units  101 , as shown in  FIG. 1 . The screen insert units  101  may be disposed in one or more openings  105   a  configured to receive screen insert units. One, two, three, or more rows of openings  105   b  that are not configured to receive a screen insert unit may be disposed between rows of the openings  105   a  configured to receive screen insert units. In still other embodiments, all openings  105  of a screen frame  100  may be configured to receive one or more screen insert units. In this embodiment, screen inert units may be disposed in all screen openings  105   a  or in a select number of openings. 
     Each opening  105  of the screen frame  100  is defined by a portion of a first longitudinal rib  109   a , a portion of a second longitudinal rib  109   b  (adjacent the first longitudinal rib  109   a  in the plurality of longitudinal ribs), a portion of a first transverse rib  107   a , and a portion of a second transverse rib  107   b  (adjacent the first transverse rib  107   a  in the plurality of transverse ribs). As noted above, one or more openings  105  are configured to receive an insert portion  150  of a screen insert unit  101 . Specifically, the first and second longitudinal ribs  109   a,b  and first and second transverse ribs  107   a,b , which define the opening  105   a , may be configured to correspond to a mating surface or surfaces of the insert portion  150  of the screen insert unit  101 . For example, the first and second longitudinal ribs  109   a,b  and first and second transverse ribs  107   a,b  may each include a feature or profile (e.g., an arrangement of surfaces, vertical, horizontal, sloped, notched, etc.) configured to collectively provide a seat  125  configured to receive and seal against the screen insert unit  101 . Examples of such features or profiles are described in detail below. 
     For example, as shown in  FIGS. 2 and 3 , in an opening  105   a  configured to receive a screen insert unit  101 , the first longitudinal rib  109   a  of the screen frame  100  may include a sloped first side surface  120  extending downwardly from a top surface  122  of the longitudinal rib  109   a  (which forms part of a top surface of screen frame  100 ) to a first sealing surface  124 . The first sealing surface  124  extends inward from the sloped first side surface  120  towards the opening  105   a  to a first inner surface  126  of the first longitudinal rib  109   a . Thus, as shown in  FIG. 3 , the first sealing surface  124  may be oriented in a generally horizontal position and the first inner surface  126  may be oriented in a generally vertical position. In some embodiments, the first sealing surface  124  may include a longitudinal groove  128 . The longitudinal groove  128  may be an upward facing groove configured to receive, locate, and facilitate securement of the screen insert  110  within the screen frame  100 . The longitudinal groove  128  may also aid in sealing against fluid flow between the screen insert unit  101  and screen frame  100 , i.e., to reduce or prevent fluid bypass of the screen insert unit  101 . In some embodiments, the longitudinal groove  128  may be defined by opposing tapered surfaces. For example, as shown, the opposing tapered surfaces of the longitudinal groove  128  may form a v-shaped notch. However, one of ordinary skill in the art will appreciate that other shapes of longitudinal grooves may be used, for example, rounded, squared, w-shaped, etc. 
     The second longitudinal rib  109   b  may include a second side surface  130  opposite the sloped first side surface  120  of the first longitudinal rib  109   a . In opening  105   a  configured to receive a screen insert unit  101 , the second side surface  130  extends downwardly from the top surface  122  of the second longitudinal rib  109   b  (which forms part of a top surface of screen frame  100 ) to a second sealing surface  134 . The second side surface  130  may be substantially vertical or may include a slope (not shown). The second sealing surface  134  extends from the second side surface  130  towards the opening  105   a  to a second inner surface  136  of the second longitudinal rib  109   b . The second sealing surface  134  may be oriented in a generally horizontal position and the second inner surface  136  may be oriented in a generally vertical position. Similar to the first sealing surface  124 , the second sealing surface  134  may include a longitudinal groove  138 . The longitudinal groove  138  may be an upward facing groove configured to receive, locate, and facilitate securement of the screen insert  110  within the screen frame  100 . The longitudinal groove  138  may also aid in sealing against fluid flow between the screen insert  110  and screen frame  100 , i.e., to reduce or prevent fluid bypass of the screen insert. In some embodiments, the longitudinal groove  138  may be defined by opposing tapered surfaces. For example, as shown, the longitudinal groove  138  of the second sealing surface  134  may be v-shaped, similar to the longitudinal groove  128  of the first sealing surface  124 ; however, one of ordinary skill in the art will appreciate that the second sealing surface  134  may have a differently shaped longitudinal groove  138  including, for example, rounded, squared, w-shaped, etc. 
     As shown in  FIG. 2 , the longitudinal rib  109   a  having a sloped first side  120  may also include a sloped second side  121  extending downwardly from the top surface  122  opposite the sloped first side  120 . The sloped second side  121  may define a portion of an adjacent opening  105 . The adjacent opening  105  may or may not be configured to receive a screen insert unit  110 . In some embodiments, the longitudinal rib  109   a  having a sloped first side  120  may include a second side that is not sloped (not shown). In other words, the second side of the longitudinal rib  109   a  may include a second side that extends vertically from the top surface  122 . As shown in  FIGS. 1-3 , the screen  100  may include one or more longitudinal ribs  109   a  having sloped first and second sides  120 ,  121  and one or more longitudinal ribs  109   b  having generally vertically disposed first and second sides. In some embodiments, the sloped sided longitudinal ribs  109   a  may be alternatingly disposed between non-sloped (vertically disposed) sided longitudinal ribs  109   b . Thus, as shown, each opening  105  may include one or more sloped surfaces, regardless of whether the opening  105  is configured to receive a screen insert unit  101 . 
     Turning now to  FIG. 4 , which is a cross-sectional side view taken along lines  4 - 4  of  FIG. 2 , a transverse side of a portion of the screen frame  100  with a screen insert  110  installed in accordance with one or more embodiments of the present disclosure is shown. In an opening  105   a  configured to receive screen insert unit  101 , the first transverse rib  107   a  includes a third side surface  207  extending downwardly from the top surface  123  of the first transverse rib  107   a  (which forms part of a top surface of screen frame  100 ) to a third sealing surface  206 . The third sealing surface  206  extends inward from the third side surface  207  towards the opening  105   a  to a third inner surface  208  of the first transverse rib  107   a . Thus, as shown in  FIG. 4 , the third sealing surface  206  may be oriented in a generally horizontal position and the third inner surface  208  may be oriented in a generally vertical position. A first bottom surface  204  extends from the third inner surface  208  towards the first transverse rib  107   a . In some embodiments, the third sealing surface  206  includes a longitudinal groove  210 , similar to the first and second sealing surfaces ( 124  and  134 ). The longitudinal groove  210  may be an upward facing groove configured to receive, locate, and facilitate securement of the screen insert unit  101  within the screen frame  100 . The longitudinal groove  210  may also aid in sealing against fluid flow between the screen insert unit  101  and screen frame  100 , i.e., to reduce or prevent fluid bypass of the screen insert unit  101 . In some embodiments, the longitudinal groove  210  may be defined by opposing tapered surfaces. For example, as shown, the opposing tapered surfaces of the longitudinal groove  210  may form a v-shaped notch. However, one of ordinary skill in the art will appreciate that other shapes of longitudinal grooves may be used, for example, rounded, squared, w-shaped, etc. 
     In opening  105   a  configured to receive screen insert unit  101 , the second transverse rib  107   b  includes a fourth side surface  217  extending downwardly from the top surface  123  (which forms part of a top surface of screen frame  100 ) to a fourth sealing surface  216 . The fourth sealing surface  216  extends inward from the fourth side surface  217  towards the opening  105   a  to a fourth inner surface  218  of the second transverse rib  107   b . Thus, as shown in  FIG. 4 , the fourth sealing surface  216  may be oriented in a generally horizontal position and the fourth inner surface  218  may be oriented in a generally vertical position. A second bottom surface  214  extends from the fourth inner surface  218  towards the second transverse rib  107   b . In some embodiments, the fourth sealing surface  216  includes a longitudinal groove  220  similar to the first, second, and third sealing surfaces ( 124 ,  134 , and  206 ). The longitudinal groove  220  may be an upward facing groove configured to receive, locate, and facilitate securement of the screen insert unit  101  within the screen frame  100 . The longitudinal groove  220  may also aid in sealing against fluid flow between the screen insert unit  101  and screen frame  100 , i.e., to reduce or prevent fluid bypass of the screen insert unit  101 . In some embodiments, the longitudinal groove  220  may be defined by opposing tapered surfaces. For example, as shown, the opposing tapered surfaces of the longitudinal groove  220  may form a v-shaped notch. However, one of ordinary skill in the art will appreciate that other shapes of longitudinal grooves may be used, for example, rounded, squared, w-shaped, etc. 
     As shown in  FIG. 5 , the first sealing surface  124  of the first longitudinal rib  109   a , the second sealing surface  134  of the second longitudinal rib  109   b , the third sealing surface  206  of the first transverse rib  107   a , and the fourth sealing surface  216  of the second transverse rib  107   b  collectively form the seat  125  configured to receive the screen insert unit  101 . Further, the longitudinal grooves  128 ,  138 ,  210 , and  220  may collectively locate and facilitate securement of the screen insert unit  101 , and reduce or prevent fluid bypass of the screen insert unit  101 . 
     The inner surfaces  126 ,  136 ,  208 , and  218  may be curvilinear in shape. For example, the first inner surface  126  protrudes outwardly towards opening  105  with ends tapering back towards the first side surface  120 . Such a curvilinear shape may allow for a wider, and thus strengthened, inner surface while still maximizing the opening  105  for fluid flow therethrough. In some embodiments, the inner surfaces  126 ,  136 ,  208 , and  218  may extend straight towards their respective side surface. For example, the first inner surface  126  may protrude outwardly towards opening  105  and extend straight back towards the first side surface  120 . Thus, while examples are shown in drawings and discussed herein, one of ordinary skill in the art will appreciate that other shaped longitudinal ribs and transverse ribs may be used without departing from the scope of embodiments disclosed herein. 
     The lower portion  150  of the screen insert unit  101  may be configured to engage with the features and/or profiles of the first and second longitudinal ribs  109   a,b  and first and second transverse ribs  107   a,b . For example, with reference to  FIGS. 3, 4, and 6 , the lower portion  150  of the screen insert unit  101  has a first side  402 , a second side  404 , a third side  403 , and a fourth side  405  which define an opening  170 . The screen insert unit  101  may also include an extending member  240  extending downwardly from a lower surface of the screen insert unit  101 . As shown in  FIGS. 3 and 4 , the extending member  240  may extend downwardly from the longitudinal ribs  104  and the transverse ribs ( 106 ,  FIG. 2 ) of the upper portion  140  of the screen insert unit  101 . The extending member  240  may be formed integrally with the screen insert unit  101  or attached to the longitudinal ribs  104  and the transverse ribs  106  of the screen insert unit  101  using methods well known in the art. The extending member  240  is substantially vertical and configured to engage one or more surfaces of the transverse ribs  107  and longitudinal ribs  109  of the screen  100 , as discussed below. Engagement of the extending member  240  of the screen insert unit  101  may be accomplished with an interference fit to secure the screen insert unit  101  with the screen frame  100 . Referring again to  FIG. 3 , the extending member  240  may be configured to engage at least one of the first inner surface  126  of the first longitudinal rib  109   a  and the second inner surface  136  of the second longitudinal rib  109   b . The extending member  240  may be hollow to allow filtered fluid flow through the screen insert unit  101 . The extending member  240  may be cylindrical (as shown in  FIGS. 2 and 6 , oval (as shown in  FIG. 9 ), square, rectangular, or any other shape without departing from the scope of embodiments disclosed herein. 
     As shown in  FIG. 3 , the first side  402  of the screen insert unit  101  also includes a sloped first side surface  152  that extends inwardly towards the opening  170  from a lower surface of the screen insert unit  101  or a first outer surface  180  of the screen insert unit  101  to a first mating surface  154 . The first mating surface  154  extends from the sloped first side surface  152  inwards towards the opening  170  to an outer surface  127  of the extending member  240 . As shown, in some embodiments, the first mating surface  154  may be oriented in a generally horizontal position while the outer surface  127  of the extending member may be oriented in a generally vertical position. The sloped first side surface  152  of the screen insert  110  is configured to engage the sloped first side surface  120  of the first longitudinal rib  109   a , the first mating surface  154  is configured to contact the first sealing surface  124  of the first longitudinal rib  109   a , and the first inner surface  126  of the first longitudinal rib  109   a  is configured to contact the outer surface  127  of the extending member  240 . While the first mating surface  154  is shown to engage the groove  128  of the first sealing surface  124 , in other embodiments, the groove  128  may be formed in the first mating surface  154  and the first sealing surface  124  of the first longitudinal rib  109   a  would be configured to contact the groove  128 . 
     The second side  404  includes a second side surface  156  of the screen insert unit  101  that extends downwardly from a lower surface of the screen insert unit  101  or a second outer surface  190  of the screen insert unit  101  to a second mating surface  158 . The second mating surface  158  extends from the second side surface  156  inwards towards the opening  170  to an outer surface  127  of the extending member  240 . As shown, in some embodiments, the second mating surface  158  may be oriented in a generally horizontal position while the outer surface  127  of the extending member may be oriented in a generally vertical position. The second side surface  156  of the screen insert unit  101  is configured to engage the second side surface  130  of the second longitudinal rib  109   b , the second mating surface  158  is configured to contact the second sealing surface  134  of the second longitudinal rib  109   b , and the second inner surface  136  of the second longitudinal rib  109   b  is configured to contact the outer surface  127  of the extending member  240 . While the second mating surface  158  is shown to engage the groove  138  of the second sealing surface  134 , in other embodiments, the groove  138  may be formed in the second mating surface  158  and the second sealing surface  134  of the second longitudinal rib  109   b  would be configured to contact the groove  138 . 
     As shown in  FIG. 4  and  FIG. 10 , which is a cross-sectional side view from a transverse side of the screen frame  100  taken along lines  10 - 10  of  FIG. 1 , the third side  403  of screen insert unit  101  includes a third side surface  181  that extends downwardly from a lower surface of the screen insert unit  101  or a first outer surface  180  of the screen insert unit  101  to a third mating surface  182 . The third mating surface  182  extends from the third side surface  181  inwards towards the opening  170  to an outer surface  127  of the extending member  240 . As shown, in some embodiments, the third mating surface  182  may be oriented in a generally horizontal position while the outer surface  127  of the extending member may be oriented in a generally vertical position. The third side surface  181  of the screen insert unit  101  is configured to engage the third side surface  207  of the first transverse rib  107   a , the third mating surface  182  is configured to contact the third sealing surface  206  of the first transverse rib  107   a , and the third inner surface  208  of the first transverse rib  107   a  is configured to contact the outer surface  127  of the extending member  240 . Similarly, the fourth side  405  of screen insert unit  101  includes a fourth side surface  185  that extends downwardly from a lower surface of the screen insert unit  101  or a first outer surface  180  of the screen insert unit  101  to a fourth mating surface  186 . The fourth mating surface  186  extends from the fourth side surface  185  inwards towards the opening  170  to an outer surface  127  of the extending member  240 . As shown, in some embodiments, the fourth mating surface  186  may be oriented in a generally horizontal position while the outer surface  127  of the extending member may be oriented in a generally vertical position. The fourth side surface  185  of the screen insert unit  101  is configured to engage the fourth side surface  217  of the second transverse rib  107   b , the fourth mating surface  186  is configured to contact the fourth sealing surface  216  of the second transverse rib  107   b , and the fourth inner surface  218  of the second transverse rib  107   b  is configured to contact the outer surface  127  of the extending member  240 . 
     As shown in  FIG. 10 , the lower portion  150  of the screen insert unit  101  has a cross-section that corresponds with the cross-section of the opening  105  into which the screen insert unit  101  will be installed. The lower portion  150  has a width “A.” The upper portion  140  has a width “B” which is greater than width “A”, thereby providing a generally Y-shaped cross section configuration of the screen insert unit  101 . The width “B” may be about twice that of width “A” or even greater in certain embodiments, thereby increasing the screening area of the screen insert unit  101  and providing the potential for higher effective fluid processing capacity of the screen frame  100 . In other embodiments, the upper portion  140  of the screen insert  110  may have a T-shaped, U-shaped, W-shaped, or other shape cross-sectional configuration. 
       FIG. 6  shows a portion of a prototype of the screen insert unit  101  to be installed in an opening (not shown) of a section of screen frame  100 . The screen insert unit  101  is located over the screen frame  100  opening to be installed into. The longitudinal and transverse side surfaces and sealing surfaces of the screen frame are located and matched to the corresponding longitudinal and transverse side surfaces and sealing surfaces of the screen insert unit  101 , as previously discussed with respect to  FIGS. 3 and 4 . The sealing surfaces of the screen frame and screen insert unit are located properly when the opposing tapered surfaces of the screen insert unit fit the corresponding longitudinal grooves of the screen frame. The screen insert unit is urged downwardly into the screen frame until the side surfaces and sealing surfaces of the screen frame mate with the corresponding side surfaces and sealing surfaces of the screen insert unit, as previously discussed with respect to  FIGS. 3 and 4 . 
     The sloped first side surface (not shown) of the frame  100  is configured to engage a corresponding sloped first side surface  152  of a lower portion  150  of the screen insert, creating an in-situ sealing mechanism after some time of apparatus operation when sediment and small solids in the fluid flow create a filter-cake in the space between the sloped first side surface  120  and the corresponding sloped first side surface  152  and thus block unwanted fluid flow between the screen insert unit and screen frame. Additionally, the sloped first side surface  120  is intended to aid the location of the screen insert unit into the screen frame during assembly. 
     Referring now to  FIGS. 4 and 8 , in some embodiments, the extending member  240  may include at least one outwardly extending clip  245  at a distal end of the extending member  240 . The at least one clip  245  may be formed integrally with the extending member  240  or attached to the extending member  240  using methods well known in the art. The at least one clip  245  extends outwardly and is configured to engage at least one of first bottom surface  204  of the first transverse rib  107   a  and the second bottom surface  214  of the second transverse rib  107   b . The at least one clip  245  may aid in securing the screen insert unit  101  to a screen frame  100 .  FIG. 4  illustrates the extending member  240  having two outwardly extending clips  245 , each on opposite sides of the extending member  240  from the other. However, one of ordinary skill in the art will appreciate that more than two outwardly extending clips  245  may be included in the extending member  240 . Further, one of ordinary skill in the art will appreciate that other features may be used to engage at least one of the first bottom surface  204  of the first transverse rib  107   a  and the second bottom surface  214  of the second transverse rib  107   b . For example, rather than clips, the distal end of the extending member  240  may include an outwardly extending, elastically deformable lip to engage at least one of the first bottom surface  204  of the first transverse rib  107   a  and the second bottom surface  214  of the second transverse rib  107   b  and further secure the screen insert unit  101  with the screen frame  100 . 
     As shown in  FIGS. 5 and 8 , the first inner surface  126  of the first longitudinal rib  109   a , the second inner surface  136  of the second longitudinal rib  109   b , the third inner surface  208  of the first transverse rib  107   a , and the fourth inner surface  218  of the second transverse rib  107   b  are configured to engage the extending member  240 . In some embodiments, the extending member may be cylindrical, however, one of ordinary skill in the art will appreciate that other shapes of extending members may be used. The extending member  240  may include two outwardly extending clips  245 , each 180 degrees from the other as shown in  FIG. 8 , or four or more outwardly extending clips  245  configured to engage a bottom surface of at least one of the first inner surface  126  of the first longitudinal rib  109   a , the second inner surface  136  of the second longitudinal rib  109   b , the third inner surface  208  of the first transverse rib  107   a , and the fourth inner surface  218  of the second transverse rib  107   b.    
     A slight pressure may be applied while urging the screen insert unit  101  into the screen frame  100  to engage the extending member  240  with at least one of the first inner surface  126  of the first longitudinal rib  109   a , the second inner surface  136  of the second longitudinal rib  109   b , the third inner surface  208  of the first transverse rib  107   a , and the fourth inner surface  218  of the second transverse rib  107   b , having an interference fit therebetween, and to engage the outwardly facing clips  245  with a bottom surface of at least one of the first inner surface  126  of the first longitudinal rib  109   a , the second inner surface  136  of the second longitudinal rib  109   b , the third inner surface  208  of the first transverse rib  107   a , and the fourth inner surface  218  of the second transverse rib  107   b.    
     Further, as shown in  FIG. 8 , at least one of the first inner surface  126  of the first longitudinal rib  109   a , the second inner surface  136  of the second longitudinal rib  109   b , the third inner surface  208  of the first transverse rib  107   a , and the fourth inner surface  218  of the second transverse rib  107   b  may include a plurality of teeth  103 . The plurality of teeth  103  are configured to grip an outer surface of the extending member  240  to further aid in securing the screen insert unit  101  with the screen frame  100 . The plurality of teeth  103  may include teeth having planar ends and/or non-planar ends. Further, the plurality of teeth  103  may be integrally formed with the inner surfaces thereof or may be fastened to the inner surfaces in a number of ways including using fasteners, adhesives, and other known attachment methods. 
       FIG. 10  shows a prototype of an individual screen insert  110  installed in an opening  105  of a section of screen frame  100 . One of ordinary skill in the art will appreciate that the screen insert unit may be welded with the screen frame to provide additional security of the connection between the screen frame and the screen insert. For example, the longitudinal and transverse side surfaces and sealing surfaces of the screen frame may be ultrasonic welded with the longitudinal and transverse side surfaces and sealing surfaces of the screen insert unit. Further, the inner surfaces of the longitudinal and transverse ribs may be ultrasonically welded to the extending member. As shown in  FIG. 10 , the extending member  240  is accessible from the top and bottom ends of the screen frame  100 . 
     While the description above provides various examples of features and profiles of a screen insert unit coupled to a screen, one of ordinary skill in the art will appreciate that various modifications to various features and profiles may be used to secure an insert to a screen and aid in providing a seal between the screen insert unit and the screen to prevent fluid bypass of the screen insert unit without departing from the scope of embodiments disclosed herein. For example, one of ordinary skill in the art will appreciate that the angle of the sloped first side surface  120  and the angle of the corresponding sloped first side surface  152  may vary depending on, for example, the desired screening surface area of the screen insert  110 , the width of an upper portion  140  of the screen insert  110 , the width of the lower portion  150  of the screen insert  110 , the width of the opening  105 , the desired or expected flow rate of material to be separated, etc. In this embodiment, the sloped first side surface  120  and the corresponding sloped first side surface  152  have the same angle. The angle of the sloped first side surface  120  and the corresponding sloped first side surface  152  may be between, for example, 10 degrees and 80 degrees. In some embodiments, the angle of the sloped first side surface  120  and the corresponding sloped first side surface  152  may be between 30 degrees and 60 degrees. In yet other embodiments, the angle of the sloped first side surface  120  and the corresponding sloped first side surface  152  may be between 10 degrees and 50 degrees or between 25 degrees and 75 degrees. One of ordinary skill in the art will appreciate that the sloped first side surface  120  and the corresponding sloped first side surface  152  may be of any degree based on a given application. A plurality of screen inserts in a modular unit may have the same or varying angles of the sloped first side surface  120  and the corresponding sloped first side surface  152  between each of the plurality of screen inserts in the modular unit. The sloped first side surface  120  and the corresponding sloped first side surface  152  need not have the exact same angle in certain embodiments. 
     Further, the screen insert units  101  may be made of any material suitable for a particular application, e.g., oilfield screens, wastewater treatment screens, food processing screens, etc. For example, glass-filled polypropylene may be used in certain embodiments. In other embodiments, glass-filled nylon may be used. Steel reinforcements may also be used inside the screen insert units  101  to add rigidity. The screen insert units  101  may be integrally molded inserts or assembled insert components. 
     Additionally, a mesh screen (not shown) may be applied to the top of the screen insert unit  110 . The mesh screen may have any sized apertures as will be appreciated by one having ordinary skill in the art. As an embodiment, the mesh screen may have mesh that is rectangular, square or oblong in shape. The mesh may be interlocking or calendared or may have a design to increase fluid flow with respect to a similar sized mesh. The mesh screen may be secured to the screen insert unit  101  prior to the screen insert unit  101  being inserted into the openings  105  of the screen frame  100 . Alternatively, the screen insert unit  101  may have mesh applied prior to being inserted into the openings  105  of the screen frame  100 . The mesh screen may be fastened to the screen insert unit in a number of ways including using fasteners, adhesives, and other known attachment methods. For example, in the case of a composite material, the mesh screen may be secured to the screen frame  100  by melting the composite material to secure the screen frame  100  to the mesh screen. A mesh screen may also be applied to the top of the screen frame  100  over cells  102  and openings  105  which do not include a screen insert unit  101 . 
     The mesh screen size (i.e., the mesh spacing) may be determined by characteristics of the particular fluid and/or particulate matter to be processed. For example, in a wellbore application, the mesh screen size may be determined by characteristics of a particular wellbore. For example, depending on the wellbore characteristics, a coarse mesh screen may be used for drilling a wellbore containing, for example, mostly gumbo (e.g., soft, sticky, swelling clay or sticky shale) and a fine mesh screen may be used for drilling a wellbore containing, for example, higher sand content. In other embodiments, different mesh sizes (i.e., mesh screen having different size openings) may be used on different surfaces of the same screen. For example, a first mesh screen size may be used to cover the screen insert unit  101  and a second mesh screen size may be used to cover the openings  105  and cells  102  which do not include a screen insert unit  101 . In other embodiments, a first mesh screen size may be used to cover an area of the screening surface nearest a proximate end of the shaker and a second mesh screen size may be used to cover an area of the screening surface nearest a distal end of the shaker. 
     Vibratory separators using conventional filtering screens may be retrofitted with high capacity filtering screens (screens and/or screen insert units) as described herein to reduce assembly time and effort. For example, conventional filtering screens, using gaskets for sealing against unwanted fluid flow between the components and requiring fittings for securing the components together, may be retrofitted with high capacity filtering screens as described herein. 
     Although only a few example embodiments have been described in detail above those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from scope of the present application. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. § 112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function.