Abstract:
Screen assemblies for vibratory separators and shale shakers, the screen assemblies in certain aspects having screening material with a protector on an outer periphery of the screening material; and methods of making such screen assemblies. This abstract is provided to comply with the rules requiring an abstract which will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims, 37 C.F.R. 1.72(b).

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention is directed to screen assemblies for shale shakers and vibratory separators and to methods for making them. 
         [0003]    2. Description of Related Art 
         [0004]    The prior art discloses a wide variety of screens and screen assemblies for use in vibratory separators and shale shakers and methods for making screen assemblies. Many of these screen assemblies employ screening material that as installed in a screen assembly can have exposed rough portions and edges. Known methods for dealing with these rough parts have included grinding the edges in an attempt to smooth them out; cutting or shearing of the screen edges; and applying hot melting tapes or adhesives to the edges. U.S. Pat. No. 6,672,2460 discloses a screen assembly with a lip that forms a rim enclosure with a blunt edge around the perimeter of the screen assembly. 
         [0005]    There are a wide variety of patents disclosing screen assemblies for shale shakers and vibratory separators, including, but not limited to, those in U.S. Pat. Nos. 5,967,336; 6,202,856; 4,909,929; 6,543,621; 6,439,392; and in U.S. application Ser. No. 10/473,262 filed Nov. 12, 2002. 
         [0006]    There has long been a need, recognized by the present inventor for an effective and efficient assemblies with edges that are easily handled and which are relatively smooth. 
       BRIEF SUMMARY OF THE INVENTION 
       [0007]    The present invention, in certain aspects, discloses a screen assembly for use in screening material on a vibratory separator in which the material is fed to the screen assembly as the screen assembly is vibrated by vibratory apparatus of the vibratory separator, the screen assembly including: a support for supporting screen mesh, the support having an outer periphery, the screen mesh having an outer edge at the outer periphery of the support, and an edge panel with a portion of the edge panel covering the outer edge of the screen mesh. In certain aspects, the vibratory separator is a shale shaker, and the material to be treated by the screen assembly is drilling fluid with drilled solids from a wellbore operation. 
         [0008]    The present invention, in certain aspects, discloses methods for making a screen assembly, the screen assembly for use in screening material to be treated by a vibratory separator, the vibratory separator having vibrating apparatus for vibrating the screen assembly to assist in treating of the material, the method including: placing screen mesh on a support, the screen mesh having an outer edge and the support having an outer periphery; and placing an edge panel on the screen mesh, a portion of the edge panel protecting the outer edge of the screen mesh. 
         [0009]    The present invention, in certain aspects, discloses a method for making a screen assembly for a vibratory separator or shale shaker, the method including: placing screen mesh within an opening of a screen support, the screen mesh having an outer edge; maintaining the screen mesh within the opening with a maintenance member; placing an edge panel within the support, the edge panel having an inner part and an outer part, an inner part of the edge panel over the screen mesh&#39;s outer edge and the outer part of the edge panel on the screen support; securing the screen mesh to the support; and securing the edge panel to the support. 
         [0010]    Accordingly, the present invention includes features and advantages which are believed to enable it to advance vibratory screen technology. Characteristics and advantages of the present invention described above and additional features and benefits will be readily apparent to those skilled in the art upon consideration of the following detailed description of preferred embodiments and referring to the accompanying drawings. 
         [0011]    Certain embodiments of this invention are not limited to any particular individual feature disclosed here, but include combinations of them distinguished from the prior art in their structures, functions, and/or results achieved. Features of the invention have been broadly described so that the detailed descriptions that follow may be better understood, and in order that the contributions of this invention to the arts may be better appreciated. There are, of course, additional aspects of the invention described below and which may be included in the subject matter of the claims to this invention. Those skilled in the art who have the benefit of this invention, its teachings, and suggestions will appreciate that the conceptions of this disclosure may be used as a creative basis for designing other structures, methods and systems for carrying out and practicing the present invention. The claims of this invention are to be read to include any legally equivalent devices or methods which do not depart from the spirit and scope of the present invention. 
         [0012]    What follows are some of, but not all, the objects of this invention. In addition to the specific objects stated below for at least certain preferred embodiments of the invention, there are other objects and purposes which will be readily apparent to one of skill in this art who has the benefit of this invention&#39;s teachings and disclosures. It is, therefore, an object of at least certain preferred embodiments of the present invention to provide the embodiments and aspects listed above and: 
         [0013]    New, useful, unique, efficient, nonobvious screen assemblies for vibratory separators and shale shakers with edges of screening material covered with a protective member; and 
         [0014]    Methods for making such screen assemblies. 
         [0015]    The present invention recognizes and addresses the problems and needs in this area and provides a solution to those problems and a satisfactory meeting of those needs in its various possible embodiments and equivalents thereof. To one of skill in this art who has the benefits of this invention&#39;s realizations, teachings, disclosures, and suggestions, various purposes and advantages will be appreciated from the following description of preferred embodiments, given for the purpose of disclosure, when taken in conjunction with the accompanying drawings. The detail in these descriptions is not intended to thwart this patent&#39;s object to claim this invention no matter how others may later attempt to disguise it by variations in form or additions of further improvements. 
         [0016]    The Abstract that is part hereof is to enable the U.S. Patent and Trademark Office and the public generally, and scientists, engineers, researchers, and practitioners in the art who are not familiar with patent terms or legal terms of phraseology to determine quickly from a cursory inspection or review the nature and general area of the disclosure of this invention. The Abstract is neither intended to define the invention, which is done by the claims, nor is it intended to be limiting of the scope of the invention or of the claims in any way. 
         [0017]    It will be understood that the various embodiments of the present invention may include one, some, or all of the disclosed, described, and/or enumerated improvements and/or technical advantages and/or elements in claims to this invention. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
         [0018]    A more particular description of embodiments of the invention briefly summarized above may be had by references to the embodiments which are shown in the drawings which form a part of this specification. These drawings illustrate certain preferred embodiments and are not to be used to improperly limit the scope of the invention which may have other equally effective or legally equivalent embodiments. 
           [0019]      FIG. 1A  is top view, partially cutaway of a screen assembly according to the present invention. 
           [0020]      FIG. 1B  is top view of the screen assembly of  FIG. 1A  with edges removed according to the present invention. 
           [0021]      FIG. 1C  is a top view of a support frame for the screen assembly of  FIG. 1A . 
           [0022]      FIG. 1D  is a top view showing the screen assembly of  FIG. 1A  on the support frame of  FIG. 1C . according to the present invention. 
           [0023]      FIG. 1E  is a top view of an edge panel for a screen assembly according to the present invention. 
           [0024]      FIG. 1F  shows the edge panel of  FIG. 1E  on the screen assembly of  FIG. 1D . 
           [0025]      FIG. 2A  is an end cross-section view of part of a screen assembly according to the present invention. 
           [0026]      FIG. 2B  is an end cross-section view of part of a screen assembly according to the present invention. 
           [0027]      FIG. 3A  is an end view of a screen support for a screen assembly according to the present invention. 
           [0028]      FIG. 3B  shows the screen support of  FIG. 3A  with screen mesh thereon according to the present invention. 
           [0029]      FIG. 4A  is a top view of a screen support according to the present invention. 
           [0030]      FIG. 4B  is a cross-section view along line  4 B- 4 B of  FIG. 4A . 
           [0031]      FIG. 4C  is a cross-section view along line  4 C- 4 C of  FIG. 4A . 
           [0032]      FIG. 5A  is an end view of screen mesh for use in a screen assembly according to the present invention. 
           [0033]      FIG. 5B  is an end view showing a screen support for supporting the mesh of  FIG. 5A . 
           [0034]      FIG. 5C  is an end view showing the screen mesh of  FIG. 5A  adjacent the screen support of  FIG. 5B . 
           [0035]      FIG. 5D  is a top view of a panel for use in a screen assembly according to the present invention. 
           [0036]      FIG. 5E  shows a screen assembly with the panel of  FIG. 5D  within the screen support of  FIG. 6C . 
           [0037]      FIG. 5F  shows the screen assembly of  FIG. 5E  in an upright position. 
           [0038]      FIG. 6  is an end cross-section view of part of a screen assembly according to the present invention. 
       
    
    
       [0039]    Presently preferred embodiments of the invention are shown in the above-identified figures and described in detail below. Various aspects and features of embodiments of the invention are described below and some are set out in the dependent claims. Any combination of aspects and/or features described below or shown in the dependent claims can be used except where such aspects and/or features are mutually exclusive. It should be understood that the appended drawings and description herein are of preferred embodiments and are not intended to limit the invention or the appended claims. On the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the invention as defined by the appended claims. In showing and describing the preferred embodiments, like or identical reference numerals are used to identify common or similar elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness. 
         [0040]    As used herein and throughout all the various portions (and headings) of this patent, the terms “invention”, “present invention” and variations thereof mean one or more embodiment, and are not intended to mean the claimed invention of any particular appended claim(s) or all of the appended claims. Accordingly, the subject or topic of each such reference is not automatically or necessarily part of, or required by, any particular claim(s) merely because of such reference. So long as they are not mutually exclusive or contradictory any aspect or feature or combination of aspects or features of any embodiment disclosed herein may be used in any other embodiment disclosed herein. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0041]    Referring now to  FIG. 1A , a perforated plate  10  has thereon a plurality of screen mesh layers  11 ,  12  and  13 , each with some rough edge portions  11   a ,  11   b ,  12   a ,  12   b , and  13   a ,  13   b , respectively. Optionally, as shown in  FIG. 1B , the rough edges have been removed. 
         [0042]      FIG. 1C  shows a screen support or frame  20  with an outer frame  22  and crossmembers  24 ,  26 .  FIG. 1D  shows the combination of the plate  10  with the screen mesh layers  11 ,  12 ,  13  secured on the screen support  20 . The plate  10  may be secured to the screen support  20  in any known way and the mesh layers  11 ,  12 ,  13  may be connected to each other and/or to the plate  10  in any known way. The screen layers  11 ,  12 ,  13  may be any known screen mesh or material suitable for use in screen assemblies for a shale shaker or vibratory separator (including, e.g., metal, fiberglass, and plastic). 
         [0043]      FIG. 1E  shows an edge panel  30  according to the present invention.  FIG. 1F  shows the edge panel  30  in place over the edges of the screening mesh layers  11 ,  12 ,  13 . The edge panel  30  may be secured in place by any suitable known method including, but not limited to, securement to the plate  10  with fasteners and/or adhesives with or without fasteners passing through the edges of the layers  11 ,  12 ,  13  and/or with or without adhesive contacting the edges of the layers  11 ,  12   13 . Any known suitable screen support or frame may be used in place of the screen support  20  and any suitable known plate or other support may be used in place of the plate  10 . 
         [0044]      FIG. 2A  shows a method according to the present invention for providing a smooth edge for a screen assembly. A screen assembly  40  according to the present invention (shown partially) has a screen support  42  with an upper ledge  44  having an upper surface  46 . A combination of layer or layers of screen mesh and a perforated plate  48  (or a layer of layers of screen mesh without a plate) is positioned on the screen support  42 . In such a position the combination  48  has an exposed edge  48   a . A border panel  47 , e.g. like the edge panel of  FIG. 1E , is placed on the ledge  44 . The border panel  47  has an inner surface  47   a  which abuts the edge  48   a  so that the edge  48   a  cannot be touched. Optionally the panel  47  has a bevelled outer edge  47   b.    
         [0045]    Optionally, as shown in  FIG. 2B , the panel  47  has a downwardly extending lip  47   c  which lies adjacent a vertical part  42   a  of the screen support  42 . the panel  47  may be made from any suitable material, e.g. metal, stainless steel, fiberglass, plastic, composite, polytetrafluroethylene, polypropylene, polyethylene, or wood. 
         [0046]      FIG. 3A  is an end or side view of a screen support  50  according to the present invention. The screen support  50  has four sides, each with a recess  52  for receiving a screen layer, a combination of screen layers, or a combination of screen layer(s) and a perforated plate.  FIG. 3B  shows a screen layer combination  54  positioned within the recesses  52 . Edges (all edges; edges  54   a ,  54   b  shown) of the screen layer combination  54  are within the recesses  52  and, to this extent, the edges are more difficult to contact than if they were not within the recesses. Optionally spaces within the recesses between the edges and outer wall of the recesses is filled with a filler  58 , e.g. plastic, epoxy, or glue. 
         [0047]      FIGS. 4A-4C  show a screen support  60  according to the present invention which has two sides  60   a ,  60   b , an end  60   c  and an end  60   d . All sides and ends include part of a recess  61  which is sized for receiving a screen or screen combination  62  (or combined layers of screen mesh with a perforated plate). Optionally an amount of filler  68  is placed in the space between the edge of the screen combination  62  and the outer edge of the recess  61 . Filler can also extend onto a top surface  60   t  of the screen support  60 . Optionally the end  60   d  may have a hook portion  60   h . In one particular aspect the top of the screen combination  62  and the top of the filler material  68  are level with each other. 
         [0048]      FIGS. 5A-5F  illustrate a method for making a screen assembly  70  according to the present invention. A screen support  71  has a top opening  72  into which a screen layer or screen combination  73  (or screen layers plus a perforated plate) is placed, e.g. supported by a maintenance member or support S. An edge panel  74  is placed over (as viewed in  FIG. 5E ) the edges of the screen combination  73  within the screen support  71 . The screen combination  73  may be secured to the screen support  71  in any suitable known manner and the panel  74  may be secured to the screen support  71  and/or to the screen combination in any suitable known manner. For example, amounts of adhesive  75   a  are used for this securement. In one particular aspect the screen combination  73  is secured to the screen support  71  by a powder coating method and the panel  74  is secured to the screen support by a powder coating method. 
         [0049]      FIG. 5F  shows the screen assembly  70  with edges of the screen combination  73  within the screen support  71  and not projecting up beyond the top surface of the screen support  71 . 
         [0050]      FIG. 6  shows (partially) a screen assembly  80  with a support frame  81  with a top member  82  having an underside  87 . A perforated plate  83  j (and screening material  84  on the plate  83 ) may be substantially flat across its surface or, as shown, it may have a bend  85  so that a top surface  86  of the plate  83  (and screening material  84 ) is level with the top of the top member  82 . 
         [0051]    The plate  83  and material  84  may be secured to the top member  82  with glue, adhesive, epoxy and/or fasteners. Optionally, filler  88  (shown by dotted line) is put in a space between an outer edge of the plate  83  (and screening material  84 ) and an inner edge  82   a  of the top member  82 . Optionally, any edge panel  89  (in dotted lines) according to the present invention is used above the inner edge of the top member  82  covering part of the screening material around the periphery of the screening material. 
         [0052]    The present invention, therefore, provides in at least some embodiments, a screen assembly for use in screening material on a vibratory separator in which the material is fed to the screen assembly as the screen assembly is vibrated by vibratory apparatus of the vibratory separator, the screen assembly including: a support for supporting screen mesh; the support having an outer periphery; the screen mesh having an outer edge at the outer periphery of the support; and an edge panel secured to the support, a portion of the edge panel covering the outer edge of the screen mesh. Such a screen assembly may have one or some, in any possible combination, of the following: a frame, and the support on and secured to the frame; the support having a peripheral ledge; the screen mesh&#39;s outer edge extending around the peripheral ledge of the support, and the edge panel on the peripheral ledge and having an inner surface abutting the screen mesh&#39;s outer edge preventing contact with the screen mesh&#39;s outer edge; the peripheral ledge having an outer side, and the edge panel having a lip projecting down adjacent the outer side of the peripheral ledge; the peripheral ledge having a top with a first top surface and a second top surface, the first top surface located interiorly of the second top surface, the first top surface lower than the second top surface, the outer edge of the screen mesh extending along the first top surface, a space formed between the outer edge of the first top surface and the second top surface, and filler material filling the space; a portion of the filler material extending onto the second top surface; the screen mesh having a top surface, the filler material having a top surface, and the top surface of the screen mesh level with the top surface of the filler material; the peripheral ledge of the support having a top member, the top member having an underside, and the outer edge of the screen mesh positioned under the underside of the top member of the peripheral ledge; the screen mesh having a bend so that a top surface of the screen mesh is level with a top surface of the top member; the screen mesh is a plurality of layers of screening material stacked together; the support having a plurality os support sides, each support side having a recess, the screen mesh having a plurality of screen sides each screen side including a portion of the outer edge of the screen mesh, and each portion of the outer edge of the screen mesh positioned in a recess of a support side; a space is located between the outer edge of the screen mesh and inner surfaces of the recesses, and filler material fills the space; and/or the vibratory separator is a shale shaker, and the material to be treated by the screen assembly is drilling fluid with drilled solids from a wellbore operation. 
         [0053]    The present invention, therefore, provides in at least some embodiments, a screen assembly for use in screening material on a vibratory separator in which the material is fed to the screen assembly as the screen assembly is vibrated by vibratory apparatus of the vibratory separator, the screen assembly including: a support for supporting screen mesh, the support having a peripheral ledge, the support having an outer periphery, the screen mesh having a top surface, an outer edge at the outer periphery of the support, the screen mesh&#39;s outer edge extending around the peripheral ledge of the support, an edge panel secured to the support, a portion of the edge panel covering the outer edge of the screen mesh, the edge panel on the peripheral ledge and having an inner surface abutting the screen mesh&#39;s outer edge preventing contact with the screen mesh&#39;s outer edge, the peripheral ledge has a top with a first top surface and a second top surface, the first top surface located interiorly of the second top surface, the first top surface lower than the second top surface, the outer edge of the screen mesh extending along the first top surface, a space formed between the outer edge of the screen mesh and the second top surface, filler material filling the space, the filler material has a top surface, and the top surface of the screen mesh is level with the top surface of the filler material. 
         [0054]    The present invention, therefore, provides in at least some embodiments, a method for making a screen assembly, the screen assembly for use in screening material to be treated by a vibratory separator, the vibratory separator having vibrating apparatus for vibrating the screen assembly to assist in treating of the material, the method including: placing screen mesh on a support, the screen mesh having an outer edge and the support having an outer periphery, the outer edge of the screen mesh at the outer periphery of the support; and placing an edge panel on the screen mesh, a portion of the edge panel protecting the outer edge of the screen mesh. Such a method may have one or some, in any possible combination, of the following: securing the support with the screen mesh and edge panel thereon to a frame, the frame positioned beneath the support; the support has a peripheral ledge, the outer edge of the screen mesh is on the peripheral ledge, the method further including placing the edge panel so that an interior surface of the edge panel abuts the outer edge of the screen mesh to protect the outer edge of the screen mesh; the peripheral ledge having an outer side, the edge panel having a lip, the method further including locating the lip adjacent the outer side of the peripheral ledge; and/or the support having a peripheral ledge, the peripheral ledge having a lower inner surface and an upper outer surface, the outer edge of the screen mesh positionable on the lower inner surface, the method further including positioning the outer edge of the screen mesh on the lower inner surface. 
         [0055]    The present invention, therefore, provides in at least some embodiments, a method for making a screen assembly, the method including: placing screen mesh within an opening of a screen support, the screen mesh having an outer edge; maintaining the screen mesh within the opening with a maintenance member beneath and supporting the screen mesh in place within the opening; placing an edge panel within the support, the edge panel having an inner part and an outer part, an inner part of the edge panel over the screen mesh&#39;s outer edge and the outer part of the edge panel on the screen support; securing the screen mesh to the support; and securing the edge panel to the support. 
         [0056]    The present invention, therefore, provides in at least some embodiments, a screen assembly including: a frame, the frame having a ledge, the ledge having a top member with an underside, a support for supporting screen mesh, the support having an outer edge, screen mesh on the support, and the outer edge of the support located beneath and connected to the underside of the top member; and such a screen assembly may include an edge panel on the frame, a portion of the edge panel covering a portion of the screen mesh. 
         [0057]    In conclusion, therefore, it is seen that the present invention and the embodiments disclosed herein and those covered by the appended claims are well adapted to carry out the objectives and obtain the ends set forth. Certain changes can be made in the subject matter without departing from the spirit and the scope of this invention. It is realized that changes are possible within the scope of this invention and it is further intended that each element or step recited in any of the following claims is to be understood as referring to the step literally and/or to all equivalent elements or steps. The following claims are intended to cover the invention as broadly as legally possible in whatever form it may be utilized. The invention claimed herein is new and novel in accordance with 35 U.S.C. § 102 and satisfies the conditions for patentability in § 102. The invention claimed herein is not obvious in accordance with 35 U.S.C. § 103 and satisfies the conditions for patentability in § 103. This specification and the claims that follow are in accordance with all of the requirements of 35 U.S.C. § 112. The inventors may rely on the Doctrine of Equivalents to determine and assess the scope of their invention and of the claims that follow as they may pertain to apparatus not materially departing from, but outside of, the literal scope of the invention as set forth in the following claims. All patents and applications identified herein are incorporated fully herein for all purposes. 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.