Patent Publication Number: US-11648588-B2

Title: Ceramic lined aperture screening panel

Description:
PRIORITY CLAIM 
     The present application claims the benefit of priority of U.S. Provisional Application Ser. No. 63/127,551, titled “Ceramic Lined Aperture Screening Panel,” filed on Dec. 18, 2020, which is incorporated herein by reference. 
    
    
     FIELD 
     The present disclosure relates generally to screening systems, or more particularly, screen panels for use in screening systems. 
     BACKGROUND 
     Screening systems are used in the mining and other industries to size and separate desired materials from less desired materials, e.g., by screening particulate materials. Certain screening systems are composed of a plurality of modular and replaceable screening media. For example, the screening media can include modular screen panels which are removably mountable to a support frame to define an overall screening surface. The screen panels include a plurality of screening apertures dimensioned to separate the desired material from less desired material. 
     During a typical screening process, the screening system is vibrated and the mixture of particulate material is deposited on the screening surface. The particulate material migrates in a preferential feed direction on the screening system, and the screening apertures allow smaller material particles to pass through the screening surface while preventing larger material particles from passing through the screening surface, thereby achieving desired sizing separation of the particulate material. 
     Certain screening panels, however, can suffer several disadvantages. For example, conventional screen panels are constructed of a frame or insert that is encapsulated by a resilient material, such as a polymeric material, such as polyurethane or rubber. However, the intense vibrations and abrasive nature of the screening process results in excessive wear that can abrade or remove material from the relatively soft polymeric materials. This wear results in premature failure of the screen panels and requires frequent monitoring, maintenance, or panel replacement. Moreover, as the screen panel wears away over time, the shape and size of the screening apertures in the screen panel changes, resulting in apertures that are no longer suitable for their original screening intent. In this regard, wear may effectively expand the screening apertures to a size which allows particles that are unacceptably large to pass through the screen panel, thus defeating the purpose of material screening panel and requiring premature repair or replacement. 
     Accordingly, a screening system including screen panels having improved wear characteristics would be useful. More specifically, screen panels that are capable of screening abrasive materials with reduced wear and long lifetime while maintaining the designed aperture geometries for the extended lifetime of the screen panel would be particularly beneficial. 
     SUMMARY 
     Aspects and advantages of embodiments of the present disclosure will be set forth in part in the following description, or may be learned from the description, or may be learned through practice of the embodiments. 
     In one example embodiment, a screening system is provided including a screen panel at least partially defining a screening surface and an aperture configured to separate material and a ceramic aperture insert mounted to the screen panel, the ceramic aperture insert at least partially defining the screening surface and the aperture. 
     In another example embodiment, a screen system is provided including a screen panel defining a plurality of apertures that extend along a vertical direction through the screen panel, each of the plurality of apertures being at least partially defined by an aperture wall of the screen panel, the screen panel further defining at least one insert recess defined above the aperture wall along the vertical direction. One or more ceramic aperture inserts are positioned within the at least one insert recess, each of the plurality of apertures being defined by an inner face of the one or more ceramic aperture inserts and the aperture wall of the screen panel, and wherein a screening surface is defined by a top surface of the screen panel and a top face of the one or more ceramic aperture inserts. 
     These and other features, aspects and advantages of various embodiments will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present disclosure and, together with the description, serve to explain the related principles. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Detailed discussion of embodiments directed to one of ordinary skill in the art are set forth in the specification, which makes reference to the appended figures. 
         FIG.  1    depicts an example screen panel with ceramic aperture inserts according to example embodiments of the present disclosure. 
         FIG.  2    depicts a perspective view of a ceramic aperture insert according to example embodiments of the present disclosure. 
         FIG.  3    depicts a cross-sectional view of a ceramic aperture insert mounted within an aperture of a screen panel according to example embodiments of the present disclosure. 
         FIG.  4    depicts a perspective view of a screen panel with ceramic aperture inserts according to another example embodiment of the present subject matter. 
         FIG.  5    depicts a side, cross-sectional view of the example screen panel of  FIG.  4    according to example embodiments of the present disclosure. 
         FIG.  6    depicts a close-up, cross-sectional view of the example ceramic aperture inserts and screen panel of  FIG.  4    according to example embodiments of the present disclosure. 
         FIG.  7    depicts a perspective view of an insert segment of the example ceramic aperture insert of  FIG.  4    according to example embodiments of the present disclosure. 
         FIG.  8    depicts a top view of the example ceramic aperture inserts and screen panel of  FIG.  4    illustrated partially in phantom according to example embodiments of the present disclosure. 
         FIG.  9    depicts a top view of an example screen panel with ceramic aperture inserts according to example embodiments of the present disclosure. 
         FIG.  10    depicts a perspective view of an example screen panel with ceramic aperture inserts according to example embodiments of the present disclosure. 
         FIG.  11    depicts a top view of an example screen panel with ceramic aperture inserts according to example embodiments of the present disclosure. 
     
    
    
     Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention. 
     DETAILED DESCRIPTION 
     Reference now will be made in detail to embodiments, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the embodiments, not limitation of the present disclosure. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments without departing from the scope or spirit of the present disclosure. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that aspects of the present disclosure cover such modifications and variations. 
     As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. The terms “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”). In addition, here and throughout the specification and claims, range limitations may be combined and/or interchanged. Such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. The singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. 
     Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “generally,” “about,” “approximately,” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or machines for constructing or manufacturing the components and/or systems. For example, the approximating language may refer to being within a 10 percent margin, i.e., including values within ten percent greater or less than the stated value. In this regard, for example, when used in the context of an angle or direction, such terms include within ten degrees greater or less than the stated angle or direction, e.g., “generally vertical” includes forming an angle of up to ten degrees in any direction, e.g., clockwise or counterclockwise, with the vertical direction V. 
     The word “example” is used herein to mean “serving as an example, instance, or illustration.” In addition, references to “an embodiment” or “one embodiment” does not necessarily refer to the same embodiment, although it may. Any implementation described herein as “example” or “an embodiment” is not necessarily to be construed as preferred or advantageous over other implementations. Moreover, each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents. 
     Referring now generally to  FIGS.  1  through  11   , aspects of the present disclosure will be described according to various example embodiments of the present subject matter. For example, aspects of the present disclosure are directed to screening systems  100  which may be used in the mining and other industries to size and separate desired materials from less desired materials, e.g., by screening aggregate material, particulate materials, or other mixtures having various particulate sizes and shapes. For example, screening system  100  may generally include support frames and additional systems for transporting screening materials, vibrating screening system  100 , and performing other actions to facilitate the screening process. For brevity, detailed discussion of these components is omitted from the present discussion. 
     As explained above, certain screening systems are composed of a plurality of modular and replaceable screening media. For example, aspects of the present subject matter are generally directed to screen panels  102  for used in screening systems, such as screening system  100 , for screening materials. These screen panels  102  may be modular and may be removably mounted to the support frame of screening system  100  to define an overall screening surface (e.g., identified generally herein by reference numeral  104 ). Each screen panel  102  may generally include or define a plurality of screening apertures  106  that are dimensioned for a particular application in order to separate desired materials from less desired materials. 
     During a typical screening process, screening system  100  vibrates one or more of screen panels  102  while a mixture of particulate material is deposited on screening surface  104 . The mixture of particulate material may migrate in a preferential feed direction on the screening surface  104 , and screening apertures  106  may allow smaller material particles to pass through screening surface  104  while preventing larger material particles from passing through screening surface  104 , thereby achieving desired sizing separation of the mixture of particulate material. 
     Increased wear life of screening media (e.g., such as screen panel  102 ) used to sort particle size in mining, aggregate, and other material processing applications is always desirable. The abrasive nature of the screening process encourages use of screen media made from materials that are highly resistant to abrasion wear. Over time, as the media wears away, the shape and size of the apertures in the media material changes resulting in undesirable variation in the size of particles passing through the screen media. Practical applications require a balance among the cost of the screen media, the wear rate of the screen media, and a tolerable amount of particle size variation for material passing through the screen media. 
     Accordingly, to address the various issues set forth above, aspects of the present subject matter are generally directed to screen panels  102  with improved abrasion and wear resistance. More specifically, screen panels  102  described herein are particularly suited to reduce wear from interaction with mixtures of aggregate screening materials, generally resulting in a longer panel lifetime and better screening performance. In addition, each of the screen panels  102  described herein includes features for reducing wear, particularly around the apertures  106  that are used to screen the material mixtures. Notably, improved abrasion and wear resistance around the apertures may result in improved screening for the lifetime of screen panels  102 , as the shape and size of the apertures  106  remain relatively constant. 
     Example screen media materials can include steel wire, stainless steel wire, rubber, and urethane elastomers. One class of materials noteworthy for their abrasion resistance are engineered ceramics. Driven by their inherent hardness, ceramics offer unparalleled resistance to abrasive wear and may be used in mining and aggregate material handling applications where severe abrasion occurs. Example aspects of the present disclosure can utilize the abrasive wear resistance of engineered ceramics to create screen media with higher degrees of open area, longer wear life, and more consistent particle size outputs. Accordingly, screen panels  102  can include, for instance, one or more ceramic aperture inserts (e.g., identified generally by reference numeral  110 ) that extend at least partially around a perimeter of at least one aperture  106  for improve wear resistance and panel durability. Various screen panels  102  and configurations of ceramic aperture inserts  110  will be described herein according to example embodiments of the present subject matter. Due to similarity between embodiments, like reference numerals may be used to refer to the same or similar features among embodiments. 
     Specifically, referring now briefly to  FIGS.  1  through  3   , an example screen panel  102  and ceramic aperture inserts  110  will be described according to example embodiments of the present subject matter. As illustrated, screen panel  102  may generally be a solid or substantially solid panel with a plurality of apertures  106  that are molded, punched, or otherwise formed within screen panel  102 . In general, screening system  100  may rely at least in part on the force of gravity during the screening process and each screen panel  102  may generally define a vertical direction V, a lateral direction L, and a transverse direction T, each of which is mutually perpendicular, such that an orthogonal coordinate system is generally defined. According to an example embodiment, the vertical direction V of screen panel  102  is substantially aligned or parallel to the force of gravity. 
     According to an example aspect of the present disclosure, screen panel  102  may include a polymer matrix  112  or other suitable support frame for maintaining the integrity of apertures  106  even through the intense screening process. In some embodiments, a reinforcing structure can be embedded within the polymer matrix  112  or attached to the polymer matrix  112  to provide strength and stiffness to the composite screening panel  102 . The polymer can be of any type such as a rubber or urethane elastomer or blends of elastomers or other suitable polymers. For example, the reinforcing structure can be made of steel, aluminum, fiber reinforced polymer, or other suitable reinforcing materials and can be shaped such that is does not interfere with the positioning of ceramic aperture inserts  106 . 
     The polymer matrix  112  surrounding the ceramic aperture inserts  110  can serve to bind together the ceramic aperture inserts  110  in predetermined patterns for optimal screening performance. For example, the polymer matrix  112  can fill the spaces between and around the ceramic aperture inserts  110 . In this regard, the polymer matrix  112  serves to separate and isolate the ceramic aperture inserts  110  and to bond the ceramic aperture inserts  110  together forming a modular screen panel  102  with defined dimensions and a well-defined aperture pattern. The polymer material can also serve to provide additional features such as attachment elements to attach screen panel  102  to a frame system. For example, in some embodiments, screen panel  102  can include features for attaching to a support system, such as one or more mounting bosses  114  (see, e.g.,  FIG.  4   ). 
     In some embodiments, screen panel  102  may further include a structural reinforcing frame (not shown) or a frame for locating ceramic aperture inserts  106 . In some embodiments, a ceramic aperture insert positioning frame can be used to create and maintain a certain spacing and pattern of the ceramic aperture inserts  110 . The positioning frame can be made of steel, aluminum, or more preferably polymer, or most preferably fiber reinforced polymer composite. The positioning frame can contain features such as tabs or grooves that engage with the ceramic aperture inserts  110 . The ceramic aperture insert positioning frame may be at least partially embedded within the polymer matrix  112 . 
     As illustrated, according to example embodiments, ceramic aperture inserts  110  can be incorporated into screen panel  102  and may extend around the entire perimeter of the apertures  106 . Therefore, the aperture size and shapes maybe defined by the characteristics of the openings in the ceramic aperture inserts  110 . The composite screen panel  102  can have defined dimensions and one or more ceramic aperture inserts  110  can be arranged in a defined pattern configured for improved overall screening process performance. For example, as illustrated in  FIG.  1   , apertures  106  are substantially circular and are each fitted with circular ceramic aperture inserts  110 . 
     As illustrated, ceramic aperture inserts  110  only extend through a portion of the height of screen panel  102 . For example, ceramic aperture inserts  110  may define a height that is less than ½, less than ¼, less than ⅛, or less, than a height of screen panel  102  as measured along the vertical direction V. By contrast, according to alternative embodiments ceramic aperture inserts  110  may extend to the entire thickness or height of screen panel  102 . According to exemplary embodiments, the height of ceramic aperture inserts  110  may be defined relative to the average aperture dimension, e.g., such as the width measured along the lateral direction L. For example, the height of ceramic aperture inserts  110  may be less than ½ of the aperture width, less than ¼ of the aperture width, less than ⅛ of the aperture width, or less. It should be appreciated that the ratio of the insert height to the aperture size (e.g., width) and the ratio of the insert height to the height of screen panel  102  may vary while remaining within the scope of the present subject matter, e.g., based at least in part on the tendency or lack of tendency for the rocks or particles to get stuck or “peg” or “plug” the apertures  106 . 
     In some embodiments, the ceramic aperture inserts  110  can be made of ceramic material such as alumina, aluminum oxide, zirconia, silicon carbide, tungsten carbide, diamond, or blends of such materials chosen for their wear resistance. The ceramic aperture insert can define a three-dimensional volume with a shape comprising an upper surface, a lower surface and an outer perimeter surface. At least one hollow opening extends through the volume from the upper surface to the lower surface forming an aperture. Although example shapes, sizes, geometries, and configurations of ceramic aperture inserts  110  are described below to facilitate discussion of aspects of the present subject matter, it should be appreciated that these inserts are not intended to be limiting in any manner. Indeed, variations and modifications to ceramic aperture inserts  110  may be made while remaining within the scope of the present subject matter. 
     According to the illustrated embodiment, screen panel  102  may generally define a screening surface  104  that is a substantially planar surface configured for receiving the mixture of particulate material. For example, according to the illustrated embodiment, screening surface  104  may be positioned above and opposite a bottom side  122  of screen panel  102  along the vertical direction V. In general, each aperture  106  may be defined by an aperture wall  124  of screen panel  102  and may extend through screen panel  102  substantially along the vertical direction V. Specifically, aperture  106  may extend from an aperture inlet  126  which is substantially coplanar with screening surface  104  and an aperture outlet  128  that is substantially coplanar with a bottom side  122  of screen panel  102 . During operation, material that is small enough to fit through aperture  106  may fall under the force of gravity through aperture inlet  126 , into aperture  106 , and out of aperture  106  through aperture outlet  128 . 
     In general, ceramic aperture inserts  110  may be embedded within, seated into, or mounted to screen panel  102  (e.g., or more particularly within the polymer matrix  112  of screen panel  102 ) in any suitable manner. For example, as best illustrated in  FIGS.  3  and  6   , screen panel  102  may generally define insert recesses  130  that are sized and configured for receiving ceramic aperture inserts  110 . More specifically, according to the illustrated embodiment, insert recesses  130  may be defined above aperture walls  124  and may be defined such that screen panel  102  defines a support shoulder  132  that is positioned below screening surface  104  along the vertical direction V, such that a bottom face  134  of ceramic aperture inserts  110  is seated on support shoulder  132 . When so positioned, a top face  136  of ceramic aperture insert  110  may be flush with screening surface  104  (e.g., may be coplanar with screening surface  104 ). By contrast, according to the illustrated embodiment, top face  136  of ceramic aperture inserts  110  may extend slightly above screening surface  104  along the vertical direction V. According to example embodiments, top face  136  of ceramic aperture insert  110  may at least partially define screening surface  104  of screen panel  102 . 
     According to example embodiments ceramic aperture inserts  110  may further define an inner face  140  that at least partially defines aperture  106 . In this regard, inner face  140  may be directly adjacent and form at least a partial boundary of aperture  106 . According to an example embodiment, inner face  140  of ceramic aperture inserts  110  may sit substantially flush with aperture wall  124  of screen panel  102 . Moreover, referring now briefly to  FIGS.  3  and  5   , inner face  140  and/or aperture wall  124  may be tapered to define a relief angle  142  relative to the vertical direction V. In this manner, for example, aperture inlet  126  may generally have a smaller cross-sectional area than aperture outlet  128 , e.g., such that relief angle  142  may facilitate the easy exit of particles passing through screen panel  102 . According to example embodiments, relief angle  142  may be between about 0.5° and 20°, between about 1° and 10°, between about 3° and 5°, or about 4° relative to the vertical direction V. Although aperture  106  is illustrated as being tapered at a fixed angle, it should be appreciated that according to alternative embodiments, aperture  106  may be stepped or have any other suitable cross-sectional geometry or profile while remaining within the scope of the present subject matter. 
     Notably, when ceramic aperture inserts  110  are positioned within insert recesses  130  of screen panel  102 , the polymer matrix  112  of screen panel  102  and the ceramic aperture inserts  110  generally define an upper screening surface  104  and extend substantially within a horizontal plane (e.g., defined by the lateral direction L and the transverse direction T). In addition, the polymer matrix  112  and ceramic aperture inserts  110  collectively define each aperture  106  and the ceramic aperture inserts  110  may be particularly suited to prevent wear or abrasion on the edges surrounding aperture inlet  126 , such that the size, shape, and geometry of apertures  106  may remain relatively constant over the lifetime of screen panel  102 . 
     According to the embodiment illustrated in  FIGS.  1  through  3   , ceramic aperture inserts  110  are formed from a single piece and are circular or rectangular in cross-sectional profile. In this regard, ceramic aperture inserts  110  may extend around an entire perimeter of aperture  106  to form a full enclosure around the aperture  106 . However, it should be appreciated that the size, shape, and geometry of ceramic aperture inserts  110  may change while remaining within the scope of the present subject matter. For example, ceramic aperture insert shapes can include hollow cylinders, rings, eyelets, squares, rectangles, or modifications thereof. Moreover, referring now generally to  FIGS.  4  through  11   , each ceramic aperture insert  110  may be formed from a plurality of insert segments (identified herein generally by reference numeral  150 ) that collectively form the ceramic aperture insert  110 . 
     For example, the plurality of insert segments  150  may generally be positioned around the perimeter  152  of each aperture  106  such that at least one perimeter gap  154  is defined between adjacent segments  150 . In this regard, as shown for example in  FIG.  5   , the ceramic aperture insert  110  can include four separate insert segments  150  (e.g., a first segment, a second segment, a third segment, and a fourth segment) that fit together to line the perimeter  152  of the aperture  106 . In alternative embodiments, the ceramic aperture insert  110  can be divided into more or fewer segments  150 . For instance, as shown in  FIGS.  9  and  11   , the ceramic aperture insert  110  can be divided into six separate segments  150  that fit together to line the perimeter of the aperture  106 . In some implementations, as shown in the figures, the different segments  150  of the ceramic aperture insert  110  can be spaced apart from one another by perimeter gaps  154  that are defined between adjacent segments  150 . However, according to alternative embodiments, perimeter gaps  154  may be eliminated and adjacent segments  150  may contact or butt directly up to each other. 
     The exact configuration of insert segments  150  may vary in order to achieve various performance objectives of a particular screen panel  102 . Aspects of the present subject matter are not restricted to any particular configuration of insert segments  150  illustrated herein. According to an example embodiment, as best illustrated in  FIGS.  4 ,  8 ,  9 , and  11   , insert segments  150  may be positioned along one or more edges of the aperture profile. More specifically, aperture  106  may have a rectangular profile (e.g., as defined within a horizontal plane or a plane that is coplanar to screening surface  104 ). According to the illustrated embodiment, insert segments  150  may be positioned along the edges  160  of these rectangular profiles. In addition, perimeter gaps  154  may generally be defined in the corners  162  of the rectangular profile of apertures  106 . According to still other embodiments, perimeter gaps  134  may also be defined between multiple insert segments  150  that are positioned along a single edge  160 . By contrast, as best illustrated in  FIG.  10   , insert segments  150  may be curved or angled at approximately 90° and positioned within corners  162  of apertures  106 . In this manner, perimeter gaps  154  may be defined along edges  160  of aperture  106 , e.g., between the ends of insert segments  150 . 
     Referring now briefly to  FIG.  11   , screen panel  102  may further define one or more panel extensions  164  that generally protrude into apertures  106 . In this regard, panel extensions  164  may be the portion of the polymer matrix  112  of screen panel  102  that extend into apertures  106  and that serve to form the perimeter gap  154  between adjacent insert segments  150 . In addition, panel extensions  164  may generally prevent large particulates from passing through aperture  106  while permitting some flexibility for moderate size particulates. Furthermore, as shown in  FIGS.  4  through  11   , perimeter gap  154  may generally be filled with a polymeric material, e.g., a portion of screen panel  102 . In this manner, screen panel  102  may fill at least one of the perimeter gaps  154  such that inner face  140  of insert segments  156  substantially flush with aperture wall  124  of screen panel  102 . 
     In general, it may be desirable to ensure that perimeter  152  of aperture  106  is largely bounded by insert segments  150 . In this regard, it may be desirable to carefully control the ratio of perimeter gaps  154  to insert segments  150 . For example, according to example embodiments, insert segments  150  may form greater than 60%, greater than 70%, greater than 80%, greater than 90%, or greater than 95% of the total linear perimeter  152  of aperture  106 . In addition, it may be desirable to regulate the average gap length relative to the length of insert segments  150 . In this regard, an average gap length  170  may be defined as the linear distance of the perimeter gaps  154  as measured along the perimeter  152  of aperture  106 . In addition, an average insert length  172  may be measured as the average length of insert segments  150  as measured along the perimeter  152  of aperture  106 . In general, the average gap length  170  may be less than ½ of the average insert length  172 , less than ¼ of the average insert length  172 , less than ⅛ of the average insert length  172 , less than 1/16 of the average insert length  172 , or less. 
     According to example embodiments, screen panel  102  may use various mechanisms and features to ensure ceramic aperture inserts  110  are securely and firmly embedded within screen panel  102 . For example, in some embodiments, the surfaces of ceramic aperture inserts may be treated with a bonding agent to facilitate adhesion to the polymer matrix  112  of screen panel  102 . Bonding agents can include any suitable material but, in some embodiments, can be silane based. For example, commercial bonding agents for ceramic to rubber bonding may include Chemlok® 6411 with Chemlok® 144 primer or Cilbond® 24. For example, for ceramic to urethane bonding, a bonding agent may include Chemlok® 213 or Cilbond® 48 or Cilbond® 49SF. Other suitable bonding agents are possible and within the scope of the present subject matter. 
     According to still other embodiments, screen panel  102  and ceramic aperture inserts  110  may define complementary recesses and/or protrusions that are intended to provide mechanical interlocking of the two components for securing ceramic aperture inserts  110  within the polymer matrix  112  of screen panel  102 . For example, as best illustrated in  FIGS.  6  through  8   , screen panel  102  may generally define one or more locking recesses  180  that are defined around aperture  106  or surrounding insert recesses  130  below screening surface  104  along the vertical direction V. In addition, ceramic aperture inserts  110  may define one or more complementary protruding features  182  that are generally configured for receipt with in the one or more locking recesses  180  to secure ceramic aperture insert  110  within screen panel  102 . In this regard, during the molding process of screen panel  102 , polymer matrix  112  may flow, form, and cure around complementary protruding features  180  to provide secure mechanical engagement of ceramic aperture inserts  110  within screen panel  102 . 
     Referring now briefly to  FIGS.  7  and  8    according to example embodiments, the one or more complementary protruding features  182  may be offset from a center of ceramic aperture insert  110  or insert segment  150 . More specifically, as best shown on insert segment  150  illustrated in  FIG.  7   , complementary protruding feature  182  may extend from an engaging face  184  of insert segment  150  (e.g., opposite inner face  140  within a horizontal plane). Complementary protruding feature  182  may be offset along the elongated dimension of engaging face  184 . In this manner, as best shown in  FIG.  8   , insert segments may be positioned immediately adjacent each other on adjacent apertures  106  while minimizing the space there between, e.g., resulting in a smaller bridge between apertures  106  and better screening performance. Although the example illustrated embodiment shows insert segments  150  as defining protruding features  182  and screen panel  102  as defining locking recesses, it should be appreciated that these two features could be swapped or alternated while remaining within the scope of the present subject matter. Moreover, the number, size, geometry, and positioning of such engaging features may vary without departing from the scope of the present subject matter. 
     In some embodiments, the ceramic aperture insert  110  shape can include additional features. For instance, the ceramic aperture insert  110  can include one or more bumps, tabs, rings, or lips that extend outward from the outer perimeter surface to enable predetermined spacing between adjacent ceramic inserts. In some embodiments, the ceramic aperture insert  110  can include one or more bumps, tabs, rings, lips, indentations, or grooves extending from the outer perimeter surface to enable mechanical interlocking with a ceramic aperture insert positioning frame. In some embodiments, the ceramic aperture insert can include one or more bumps, tabs, rings, lips, indentations, or grooves extending from the outer perimeter surface to enable mechanical interlocking with the polymer matrix  112  of screen panel  102 . 
     While the present subject matter has been described in detail with respect to specific example embodiments thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing may readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, the scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations and/or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art.