Patent Description:
Various aspects and features of the present disclosure are described herein with reference to the drawings. Like numbers refer to like, but not necessarily the same or identical, elements throughout.

The embodiments disclosed herein are not necessarily in accordance with the invention which is defined by the screen basket apparatus of claim <NUM> and the method of forming a screen basket apparatus of claim <NUM>.

The present disclosure relates to apparatuses and methods for filtering, and particularly to the use of improved screen baskets to be used in methods and systems for sorption of metals from metal-containing ore. Embodiments of the present disclosure may be utilized with carbon-in-pulp (CIP), carbon-in-leach (CIL), and resin-in-leach (RIL) systems, among others. CIL and CIP systems are, for example, two counter-current methods for adsorbing leached gold from a pulp stream onto activated carbon. In such CIL and CIP processes, a plurality of adsorption tanks are placed in a series. Pulp flows continuously from the first tank of this series to the last tank. Simultaneously, carbon is pumped counter-current from the last tank of the series to the first tank. CIP and CIP processes differ in the extent to which gold is leached prior to carbon adsorption. For example, in CIL operation, carbon is added to the leaching tanks, and the leaching reaction and adsorption occur simultaneously. In contrast, in the CIP process, the majority of the leachable gold is leached out before the first adsorption stage.

A description of a general process of recovering gold from a gold-bearing ore, employing a combined cyanidation and adsorption treatment, may be found in <CIT>. Although embodiments of the present disclosure are generally discussed with reference to gold or carbon, embodiments of the present disclosure may be equally applied to processes for recovering silver, iron, nickel, and other metals from the appropriate ore. The recovery of any metal from a mined ore is within the scope of the present disclosure.

A description of existing metal screen baskets and methods of use thereof in the above-described CIP processes may be found in <CIT>. The process described in <CIT> have generally become known in the art as "NKM" vertically swept interstage screening processes, and the screen baskets used therein have generally become known in the art as NKM screen baskets. Generally, such NKM screen baskets include a metal support frame provided with a wedge wide screen wrapped around a peripheral sidewall thereof. The wedge wire screen is used to filter materials from a metal-rich pulp. The screen basket is attached to an NKM screening device, and a lower portion of this NKM screening device, including the attached NKM screen basket, is immersed in a tank containing carbon-in-pulp material. Impellers on the NKM screening device cause the pulp in the tank to follow through the wedge wire screen and into the interior of the NKM screen. However, the wedge wire screen has a very low open screening area, which leads to inefficient screening. The low open screening area also leads to clogging. Clogging, in turn, forces increased volumes of pulp to flow through the unclogged areas of the wedge wire screen, which increases the wear rate of the screen. Additionally, the individual wires that form the wedge wire screens tend to deteriorate or break over time due to forces encountered during screening processes, such as sweeping of internal and external propulsion blades. Further to the background prior art, the document <CIT> describes a shaker screen filter for a well fluid shale shaker, which includes a main frame arranged for being arranged in the well fluid shale shaker for screening, preferably under vibration, of drilling mud, wherein the mainframe is subdivided into a plurality of smaller cell frames, one or more cell plug filters with one or more layers of screen cloths on top of at least one support cloth or support layer, wherein each of the cell plug filters includes a cell plug filter frame arranged to be held in each of the cell corresponding frames of the main frame.

In exemplary embodiments of the present disclosure, an improved screen basket device for screening material is provided. The device comprises a support frame having a substantially closed bottom and an open top, and a substantially cylindrical sidewall support portion extending between the bottom and top of the support frame. The support frame may be metal, such as stainless steel. A polyurethane screen sidewall extends around and is supported by the sidewall support portion. The polyurethane screen sidewall comprises a high open-area polyurethane screen. In certain embodiments, the polyurethane screen sidewall substantially encloses the sidewall support portion between the closed bottom and open top to thereby provide a maximized screening area. The polyurethane screen sidewall may be affixed to an outer periphery of the sidewall support portion.

The polyurethane screen sidewall may be formed from a plurality of individual polyurethane screen members. These individual polyurethane screen members may be aligned adjacent to one another to provide a generally continuous screening area across the screen sidewall. In one example, the plurality of individual polyurethane screen members may include eight individual polyurethane screen members. In such embodiments, these eight individual polyurethane screen members may be arranged such that four of the screen members are on a lower half of the support frame and four of the screen members are on an upper half of the support frame.

In certain embodiments, the substantially closed bottom may be provided with a centralized aperture that allows receipt of the drive shaft of an NKM apparatus.

The high open-area polyurethane screen member, in certain embodiments, comprises a flexible molded polyurethane body; screen openings in the body; a set of first, substantially parallel flexible members defining opposite first sides of the screen openings; a set of second, substantially parallel flexible members defining second opposite sides of the screen openings, whereby the second members are substantially perpendicular to the second members; a set of third, substantially parallel members having multiple first members therebetween; a set of fourth, substantially parallel members having multiple second members therebetween; side edge portions substantially parallel at opposite sides of the body, between which the third members therein extend; and a first end portion and a second end portion substantially parallel at opposite ends of the body, between which the fourth members therein extend, whereby the end portions are substantially perpendicular to the edge portions. Screen openings in the flexible molded polyurethane body of the polyurethane screen member may be about <NUM> to about <NUM> between inner surfaces of the first members, and about <NUM> to about <NUM> between inner surfaces of the second members.

The polyurethane screen member can also include reinforcement members molded integrally within at least one of the first and third members and at least one of the second and fourth members. In some embodiments, the reinforcement members integrally formed within the first members may have a substantially uniform thickness having a magnitude in the range of about <NUM> inches to about <NUM> inches (about <NUM> to about <NUM>). The reinforcement members molded integrally with the second members may have a substantially uniform thickness having a magnitude in a range of about <NUM> inches to about <NUM> inches (about <NUM> to about <NUM>). The reinforcement members may be embodied in, for example, rods that can be molded integrally with the members. The reinforcement members may also be embodied in, for example, aramid fibers that are at least one of a twisted and a woven multistrand, with the fibers having a linear density of about <NUM> denier to about <NUM> denier.

The side edge portions of the polyurethane screen member may be configured for use in attaching the screen member to the support frame. A plurality of enlarged polyurethane ribs can be integrally formed on an exterior surface of the polyurethane screen body, with the ribs arranged substantially vertical relative to the sidewall support portion. Each of the plurality of ribs may extend substantially from a top to a bottom of the polyurethane screen member.

In further embodiments of the present disclosure, a basket cage may be provided that includes a tubular, or substantially cylindrical grid frame with multiple openings. The multiple openings in the grid frame can be arranged in a square lattice, and each one (or, in some embodiments, at least some) of the multiple openings can have a square shape. In an example embodiment, the multiple openings can include <NUM> square openings. A subset of the multiple openings can be defined by longitudinal members and transversal members. A second subset of the multiple openings can be defined by longitudinal members and transversal segments of a first annular section of the grid frame, and, similarly, a third subset of the multiple openings can be defined by longitudinal members and transversal segments of a second annular section of the grid frame.

The basket cage may feature flanges at the top and bottom of the cage. The top flange and openings can permit or otherwise facilitate mounting a plate or another type of cover on the flange. In addition or in other embodiments, the flange and openings can permit or otherwise facilitate mounting the basket cage into a screen separator machine (e.g., an NKM vertically swept interstage apparatus).

The basket cage can be utilized in a separation process to separate specific particulate matter from slurry or another type of fluid source. To that end, in one embodiment, screening cartridge assemblies can be mounted to the basket cage, where the screening cartridge assemblies can permit or otherwise facilitate the separation of specific particulate matter from the slurry. Each one of the screening cartridge assemblies can be mounted or otherwise affixed to a respective group of grid members that define, at least in part, a respective opening of the grid frame. For openings in a row about the longitudinal axis of the grid frame, a group of grid members that support a first one of the screening cartridge assembles can have a common grid member with another group of grid members that support a second one of the screening cartridge assemblies.

In some embodiments, each one of the multiple screening cartridge assemblies mounted or affixed to the grid frame includes a screening assembly and a case (or another type of container) configured to receive and hold the screen assembly. In some embodiments, the case can be embodied in a single injection molded piece integrally formed by means of injection molding a polyurethane, a thermoset polymer, or other types of polymer. Example embodiments of the injection molded piece and the process of forming the injection molded piece are discussed in more detail in the disclosures of <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, and the cross-references included therein.

The screen assembly has, in some embodiments, three individual screen units. The case includes a first opening configured to receive and/or fit the screen assembly within the case, and a second opening that permits exposing a screening surface of the screen assembly to an exterior of the grid frame. The case also includes ridges that extend from a first edge of the case, near the first opening, to an opposing second edge of the case. The ridges and respective portions of the case form respective recesses that permit or otherwise facilitate mounting (e.g., gripping or clipping) the case to the grid frame.

The entirety or substantially the entirety of the grid frame of the screen basket can be covered with screening cartridge assemblies in operation of a separation process. As such, in an example embodiment, <NUM> screening cartridge assemblies can be mounted to the respective <NUM> square openings in the grid frame.

Further, the case can include an attachment frame section and a holder frame section. The holder frame section can receive and/or hold the screen assembly formed by screen units. The attachment frame section can include a set of ridges that form respective recesses, which in turn permit or otherwise facilitate attachment (e.g., by clipping, clutching, or otherwise engaging) of the screening cartridge assembly to a grid frame.

Screen cartridges according to the present disclosure may be any suitable shape for attachment to a grid frame of a basket cage. For example and without limitation, the screen cartridges may be of a square shape, or rectangular, or ovular, or any other shape. Although example embodiments may provide for screen cartridges that are shaped to substantially match the grid openings of the grid frame (i.e., a square screen cartridge on a grid frame with square grid openings), screen cartridges of varying shapes may be affixed to grid openings a different shape. Similarly, the grid frame of the basket cage may be of any suitable shape for screening.

Screen elements and screen cartridges according to the embodiments discussed herein resist wear, abrasion, bending, and chemicals better than metal, and thus tend to last longer than wedge wire frames in CIL processes. Screen elements as discussed herein also allow for the formation of significantly smaller screen openings than those of conventional wedge wire frames, which in turn improves screening efficiency. Use of the screen members as described herein provides for significantly larger screening areas, and significantly reduces blinding as compared to conventional wedge wire screen baskets. In use, screen elements and screen cartridges as described herein also allow for a substantially consistent distance between the external propulsion blades of the screening apparatus and the screening cartridge assembly, thereby reducing clogging and elongating the life of the screen elements.

Referring now to the embodiment shown in <FIG>, the screen basket <NUM> of the present disclosure comprises a basket frame structure <NUM> that has a high open-area polyurethane screen <NUM> attached thereto.

As indicated in <FIG>, the basket frame <NUM> generally has a cylindrical configuration, although other shapes may be used. The basket frame <NUM> may preferably be formed of stainless steel, although other materials may be used. The frame has an upper end <NUM> and a lower end <NUM>, and includes a plurality of vertical support members <NUM> forming a vertical support portion extending between the upper and lower ends <NUM>, <NUM> of the frame <NUM>. As shown in <FIG>, the vertical support portion of the frame <NUM> has an interior side <NUM> and an exterior side <NUM>.

As shown in <FIG>, the support of the basket frame <NUM> may be formed from a plurality of the vertical support members <NUM> and a plurality of horizontal support members <NUM>. The embodiment shown in <FIG> includes four primary support members <NUM> spaced along a periphery of the frame <NUM>, along with a plurality of secondary support members <NUM> spaced between the primary support members <NUM>. Together, the primary and secondary support members <NUM>, <NUM> join the upper and lower ends <NUM>, <NUM> of the frame <NUM> in a spaced arrangement. The horizontal support members <NUM> may be provided by a plurality of annular rings or curved sections that are joined end-to-end to form a plurality of annular rings in a spaced relationship throughout the basket frame <NUM>.

As shown in <FIG>, each of the vertical support members <NUM> may include an interior strut portion <NUM>. The interior strut portion <NUM> may, in turn, include apertures <NUM> therethrough. The horizontal support members <NUM> pass through the apertures <NUM>, thus maintaining the horizontal support members <NUM> in a stacked and spaced arrangement.

As shown in the top view of <FIG>, the upper end <NUM> of the frame <NUM> is provided with an opening to allow for use in receiving and processing materials within the screen basket <NUM>. The lower end <NUM> of the frame <NUM> is provided with a substantially solid or closed bottom <NUM> for retaining materials in the screen basket <NUM> during processing. The substantially closed bottom <NUM> may be provided with a centralized aperture <NUM> for use in operational arrangements with shafts of processing machines, as discussed in more detail below.

Embodiments of the disclosure may include a high open-area polyurethane screen <NUM> attached to a periphery of the frame <NUM>, thereby forming a screen basket <NUM> having an open top, a substantially solid or closed bottom <NUM>, and a polyurethane screen sidewall <NUM>.

Polyurethane screen <NUM> may be provided in the form of separate, smaller screen members <NUM>, due to potential size constraints in the molding process of the polyurethane screen <NUM>. For example, as in the embodiment shown in <FIG>, polyurethane screen <NUM> may feature a plurality of separate screen members <NUM>. Each screen member <NUM> is attached to the vertical support of the frame <NUM>.

<FIG> show features of an example embodiment of a screen member <NUM> configured for use in forming the polyurethane screen sidewall <NUM> of a screen basket <NUM>. <FIG> show the exterior and interior sides of an embodiment of the screen member <NUM>, respectively, while <FIG> shows a side view of an embodiment of the screen member <NUM>. The screen member <NUM> may comprise polyurethane screens described in more detail in the following patents and patent publications, which share a common assignee with the present disclosure: <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>.

As shown in <FIG>, an embodiment of the present disclosure may provide for a screen member <NUM> with a body <NUM> of molded polyurethane having unperforated side edge portions <NUM>, <NUM>. Side edge portions <NUM>, <NUM> may each have an integral side ridge portion <NUM> for use in sealing adjacent screen members <NUM> to one another and for securing screen members <NUM> to the basket frame <NUM>, as shown in <FIG>. Each side edge portion <NUM>, <NUM> may include a cast-in structural member for use in reinforcing the side ridge portion <NUM>. Side edge portions <NUM>, <NUM> may also be formed without cast-in structural members or may include other structural members. Side ridge portions <NUM> may be in any suitable shape for attachment to a basket frame <NUM>. In an exemplary embodiment, side ridge portions <NUM> may include a formed member, e.g., a metal member that is bent to a desired shape, e.g., a U-shape member, an L-shape member, a C-shape member, or the like. The formed member may be attached to the polyurethane body by heating, pressing, mechanical, chemical, molding, and/or any other suitable method or arrangement.

Body <NUM> of screen member <NUM> also includes a lower edge portion <NUM> and an upper edge portion <NUM>, which, in combination with side edge portions <NUM>, <NUM>, define an outer border of the screen member <NUM>. In certain embodiments, side ridge portion <NUM> may extend the entire length between upper edge portion <NUM> and lower edge portion <NUM>.

Body <NUM> further includes an exterior surface <NUM> and an interior surface <NUM>. <FIG> depicts an exterior surface <NUM> of the body <NUM> when screen member <NUM> is affixed to the basket frame <NUM>, as shown, for example, in <FIG>, and <FIG> depicts an interior surface <NUM> of the body <NUM> when screen member is affixed to the basket frame <NUM> as shown, for example, in <FIG>. Body <NUM> includes first members <NUM> and second members <NUM> forming screen openings <NUM>, as shown in detail in <FIG>. First members <NUM> and second members <NUM> may, in some embodiments, be configured to include reinforcement members <NUM>, as discussed in more detail below. As shown in the side view of <FIG>, screen element <NUM> may further include vertical ribs <NUM> on the exterior surface <NUM> of screen element <NUM>. Screen element <NUM> may, however, not include vertical ribs <NUM> in certain embodiments of the present disclosure.

Body <NUM> may further include third members <NUM> and fourth members <NUM>. Third members <NUM> and fourth members <NUM>, and vertical ribs <NUM> if present, may also include reinforcement members <NUM>, discussed in more detail below. Third members <NUM>, fourth members <NUM>, and vertical ribs <NUM> may, however, not include reinforcement members <NUM> in certain embodiments of the present disclosure. Third members <NUM> and fourth members <NUM> are generally configured to provide support to the screen openings <NUM> formed by first and second members <NUM>, <NUM>.

<FIG> shows a portion of an embodiment of screen element <NUM>, with <FIG> depicting an enlarged view of a portion of <FIG>. As shown in the detail view of <FIG>, first and second members <NUM>, <NUM> form a first integrally molded grid structure <NUM> that defines screen openings <NUM>. Third and fourth members <NUM>, <NUM> may form a second integrally molded grid structure <NUM>, and fifth and sixth members <NUM> and <NUM>, respectively, may in turn form a third integrally molded grid structure <NUM>.

Reinforcement members <NUM> may be incorporated into desired members of the screen element <NUM>. Reinforcement members <NUM> provide stability to screen element <NUM> by preventing the side edges <NUM>, <NUM> from deforming and/or hour-glassing. In an exemplary embodiment, reinforcement members <NUM> may be integrated (such as by molding integrally) with the appropriate members. Reinforcement members <NUM> may be made of plastic, metal, polymer, or any other suitable material with the necessary structural properties. For example, the reinforcement members <NUM> may be embodied in rods that are molded integrally with the screen members. The reinforcement members <NUM> may also be embodied in aramid fibers that are at least one of a twisted multistrand and a woven multistrand, such that the fibers act as wicks to absorb the polyurethane molded around it, thereby providing a strong bond therewith. The twisted or woven multistrand fibers may have a linear density of about <NUM> denier to about <NUM> denier, and may preferably be approximately <NUM> denier. When an aramid fiber is used in embodiments of the present disclosure, it may be a set of aramid fibers commercial obtainable under the trademark KEVLAR® of the DuPont Company. Reinforcement members <NUM> may also be at least one of the aramid fibers commercially obtainable under the commercial names TWARON, SULFRON, TEIJINCONEX, and TECHNORA of the Teijin Company. The flexibility of the aramid fibers provides a flexible reinforcement system for the molded polyurethane, which is able to return to its original molded shape after the necessary bending and flexing that occurs during handling and installation. In certain embodiments, reinforcement members <NUM> may be tensioned before polyurethane is molded around it.

Referring back to the example embodiment shown in <FIG>, and the detail view shown in <FIG>, grid structures <NUM> and <NUM> include bi-directionally integrally molded members forming support grids within the members. Due to the properties of the reinforcement members <NUM> and the configuration of the bi-directional grid structure, the members may have a relatively small size and thus provide for increased open screening area. The grid structures provide screen strength and support for openings <NUM> during vibratory loading, and significantly increase open screening area.

As shown in the detail view of <FIG>, first members <NUM> may extend transversely between side edge portions <NUM>, <NUM>, in a manner substantially parallel with each other. Second members <NUM> may extend transversely between the lower edge portion <NUM> and the upper edge portion <NUM>, in a manner substantially parallel with each other and substantially perpendicular to first members <NUM>. In certain embodiments, second members <NUM> may have a thickness greater than that of the first members <NUM> to provide additional structural support to screen openings <NUM>.

As referred to above, and as shown in the exploded isometric view of <FIG>, first members <NUM> and/or second members <NUM> may include reinforcement members <NUM>, and may or may not be supported by additional support members or support grid structures. For example, as shown in <FIG>, which depicts a fragmentary cross-sectional view of body <NUM> of screen member <NUM>, body <NUM> has first and second members <NUM>, <NUM> with bi-directional reinforcement members <NUM> molded integrally therewith. Reinforcement members <NUM> molded integrally therewith first members <NUM> have a thickness in the range of about <NUM> inches to about <NUM> inches (about <NUM> to about <NUM>. Reinforcement members <NUM> molded integrally therewith second members <NUM> (not shown) have a thickness in the range of about <NUM> inches to about <NUM> inches (about <NUM> to about <NUM>). Such configurations may be beneficial for screening applications requiring screens with larger screen openings.

Embodiments of the present disclosure may incorporate reinforcement members <NUM> in any one of first, second, third, and fourth members <NUM>, <NUM>, <NUM>, <NUM>, as well as ribs <NUM>, and may be incorporated into either all or a portion of the first, second, third, and fourth members <NUM>, <NUM>, <NUM>, <NUM> and rib members <NUM>.

As shown in <FIG> and detail <FIG>, screen openings <NUM> may be elongated, with a greater length dimension along sides and between ends thereof than the width dimensions. Screen openings <NUM> may be approximately <NUM> to about <NUM> in width, the width being the dimension between the inner surfaces of adjacent first members <NUM>. Screen openings <NUM> may be approximately <NUM> to about <NUM> in length, the length being the dimension between the inner surfaces of adjacent second members <NUM>. Screen openings <NUM> may additionally have a variety of different shapes. For example, screen openings <NUM> may have a rectangular shape, or a square shape, or an ovular shape, or any other shape that may be formed by the first and second members <NUM>, <NUM>. The overall dimensions of screen element <NUM> may be about <NUM> meters by <NUM> meters, or may be of any other desired size. It may be understood that all dimensions set forth herein are by way of example only, and not of limitation.

Referring briefly to <FIG>, screen openings <NUM> may diverge downwardly between exterior surface <NUM> and interior surface <NUM>, with the first members <NUM> being substantially in the shape of inverted trapezoids. This general trapezoidal shape of first members <NUM> prevents blinding in screen element <NUM> and overall polyurethane screen <NUM>. First members <NUM> may include reinforcement members <NUM> molded integrally therewith, as shown in <FIG>, or may optionally not include reinforcement members <NUM> molded integrally therewith, as shown in <FIG>.

As illustrated in the detail view of <FIG>, third and fourth members <NUM>, <NUM> may have a thickness greater than first and second members <NUM>, <NUM>. The increased thickness of third and fourth members <NUM>, <NUM> may provide additional structural support to first and second members <NUM>, <NUM>. As shown in the example embodiment of <FIG>, third members <NUM> may extend transversely between the side edge portions <NUM>, <NUM> in a manner substantially parallel with each other, and may have multiple first members <NUM> featured therebetween. Fourth members <NUM> may extend transversely between lower edge portion <NUM> and upper edge portion <NUM> in a manner substantially parallel with each other, and may have multiple second members <NUM> featured therebetween. Reinforcement members <NUM> may be molded integrally with third and fourth members <NUM>, <NUM>. Third and fourth members <NUM>, <NUM> may be configured to have a minimal thickness through inclusion of reinforcement members <NUM>, while maintaining the necessary structural support for screen openings <NUM> formed by first and second members <NUM>, <NUM> during vibratory screening applications. The bi-directional support system provided by third and fourth members <NUM>, <NUM> and the added support of reinforcement members <NUM> integrated therein, where included, greatly reduces the thickness of the support members and provides for increased open screening area and overall screen efficiencies.

Body <NUM> may further include a plurality of vertical ribs <NUM>. In the embodiment shown in <FIG>, a series of nine ribs <NUM> may be provided. Ribs <NUM> may have a thickness greater than that of third and fourth members <NUM>, <NUM>, and may have a portion extending away from the interior surface <NUM> of body <NUM>. As shown in <FIG>, ribs <NUM> may also be provided extending away from the exterior surface <NUM> of body <NUM> and thus providing vertical support along the exterior screen sidewall <NUM>. The greater thickness and positioning of ribs <NUM> provides additional structural support to first and second members <NUM>, <NUM>.

Ribs <NUM> may extend transversely between the lower edge portion <NUM> and the upper edge portion <NUM> in a manner substantially parallel to each other, and may have multiple fourth members <NUM> therebetween. Ribs <NUM> may, additionally and in the alternative, extend transversely between the side edge portions <NUM>, <NUM> in a manner substantially parallel to each other, and may have multiple third members <NUM> therebetween. Ribs <NUM> may have reinforcement members <NUM> molded integrally therein. Ribs <NUM> may be provided for additional support to screen openings <NUM>, and may be configured to have a minimal thickness through inclusion of reinforcement members <NUM>, while providing the necessary structural support to maintain screen openings <NUM> during vibratory screening applications. Like third and fourth members <NUM>, <NUM>, provision of a support system of ribs <NUM> greatly reduces the thickness of the support members and provides for increased open screening area and overall screen efficiencies.

Various configurations of reinforcement members <NUM> may be provided in the support rib members <NUM> to add stability to screen member <NUM>. Reinforcement members <NUM> provided in the support rib members <NUM> may be an aramid fiber (or individual filaments thereof), a naturally occurring fiber, or other material having relatively large tensile strength with relatively small cross-sectional areas.

Each element of screen element <NUM> able to incorporate such reinforcement members <NUM> may include zero, one, or multiple reinforcement members <NUM>, and the reinforcement members <NUM> used therein may be of different sizes and materials. Reinforcement members <NUM> may be located in the bottom halves of the members so as not to be exposed relatively early during the life of the screen element <NUM>, as the upper surface of the screen may wear.

The inclusion of the reinforcement members <NUM>, as well as the support framework of the bi-directional support members, allows the first members <NUM>, as well as second members <NUM>, to be relatively thin, creating larger screen openings. Embodiments as described herein have relatively large tensile strengths with relatively small cross-sectional areas. The making of the support members and the thin first members <NUM> results in the screen member <NUM> and overall screen <NUM> having a greater percentage of open area, which, in turn, increases the capacity of the system. Open screening areas according to the embodiments described herein may range, for example, from about <NUM> percent to about <NUM> percent of the screen.

According to an embodiment of the present disclosure, a vibratory screen <NUM> includes a flexible molded polyurethane body <NUM> having substantially parallel side edge portions <NUM>, <NUM> at opposite ends of body <NUM>, as well as a lower edge portion <NUM> substantially perpendicular to the side edge portions <NUM>, <NUM>, and an upper edge portion <NUM> substantially perpendicular to the side edge portions <NUM>, <NUM> and opposite the lower edge portion <NUM>. Polyurethane body <NUM> further includes an exterior surface <NUM> and interior surface <NUM>. First and second members <NUM>, <NUM> are provided, forming screening openings <NUM>. The first members <NUM> extend between the side edge portions <NUM>, <NUM>, and the second members <NUM> extend between the lower and upper edge portions <NUM>, <NUM>. The body <NUM> may also include third and fourth members <NUM>, <NUM>, with the third and fourth members <NUM>, <NUM> having a thickness greater than that of first and second members <NUM>, <NUM>. Third members <NUM> run substantially parallel to each other and extend transversely between the side edge portions <NUM>, <NUM>, and have multiple first members <NUM> featured therebetween. Fourth members <NUM> run substantially parallel to each other and extend transversely between lower and upper edge portions <NUM>, <NUM>, and have multiple second members <NUM> featured therebetween. Reinforcement members <NUM> may be molded integrally with the third and/or fourth members <NUM>, <NUM>, and additionally reinforcement members or rods may be molded integrally with fourth members <NUM>. Body <NUM> also includes ribs <NUM>. Ribs <NUM> may be substantially parallel to each other and extend transversely between the side edge portions <NUM>, <NUM>. Ribs <NUM> may also be substantially parallel to each other and extend transversely between the lower and upper edge portions <NUM>, <NUM>. Ribs <NUM> have a thickness greater than the third and fourth members <NUM>, <NUM>, and may include reinforcement members <NUM> molded integrally therewith. Body <NUM> may additionally feature fifth and sixth members <NUM>, <NUM>. Fifth members <NUM> run substantially parallel to each other and extend transversely between the side edge portions <NUM>, <NUM>, and have multiple third members <NUM> featured therebetween. Sixth members <NUM> run substantially parallel to each other and extend transversely between lower and upper edge portions <NUM>, <NUM>, and have multiple fourth members <NUM> featured therebetween. Reinforcement members <NUM> may be molded integrally with the fifth and/or sixth members <NUM>, <NUM>, and additionally reinforcement members or rods may be molded integrally with sixth members <NUM>.

Screen members according to this embodiment may have open screening areas greater than <NUM> percent, and mesh sizes ranging from approximately <NUM> mesh to approximately <NUM> mesh. By way of example, screens tested having the aforementioned configurations included a <NUM> mesh size screen, a <NUM> mesh size screen, and a <NUM> mesh size screen. Each of these screens had open screening areas ranging from approximately <NUM> percent to approximately <NUM> percent. Such large screening areas for such relatively fine mesh sizes are achieved through the relatively strong and thin grid framework created by the third, fourth, fifth, and sixth members <NUM>, <NUM>, <NUM>, <NUM>, and by reinforcement members molded integrally therewith.

In the aforementioned embodiments and examples, the size of each grid unit formed by the intersection of the third and fourth members <NUM>, <NUM> is approximately <NUM> inch by <NUM> inch (approximately <NUM> by <NUM>). Generally, grid units may be larger for screens with larger screen openings and grid units may be smaller for screens with smaller screen openings. This principle may be generally applicable for each example embodiment discussed herein. Grid units may also have a generally rectangular shape, or may have any other suitable shape for supporting the screen openings.

The use of polyurethane screen members <NUM> as described herein to form a screen sidewall <NUM> on a basket frame has significant advantages over conventional wedge wire screens. Polyurethane screen members <NUM> as described herein resist wear, abrasion, bending, and chemicals better than metal, and thus tend to last longer than wedge wire frames in CIL processes. Polyurethane also allows for the formation of significantly smaller screen openings than those of conventional wedge wire frames, which in turn improves screening efficiency. Use of the polyurethane screen members <NUM> as described herein provides for significantly larger screening areas, and significantly reduces blinding as compared to conventional wedge wire screen baskets.

In operation, the screen basket <NUM> described herein may be used with known CIP and CIL devices and processes, such as those described in <CIT>. For example, as shown in <FIG>, the screen basket <NUM> is attached below a volute portion of an NKM vertically swept interstage apparatus. A drive shaft of the NKM apparatus passes from the top to the bottom of the screen basket <NUM>, and through the centralized opening in the closed bottom of the screen basket <NUM>. A gearbox and motor is positioned above the volute to power the drive shaft. A launder interface is situated above the polyurethane screen and volute interface to receive flow of pulp discharge.

With the screen basket <NUM> attached to the NKM apparatus, the lower portion of the NKM device, including the screen basket <NUM>, is inserted into and suspended over a large adsorption tank containing slurry of pulp to be processed. The level of the pulp in the tank is higher than the level of the fluid in the screen basket <NUM>. This arrangement causes the pulp to naturally flow through the screen of the screen basket <NUM> in an effort to equalize the fluid levels in the pulp tank and the screen basket <NUM>. Blades on the outside of the NKM unit rotate within the tank around an outer periphery of the screen sidewall of the screen basket <NUM>. The outside blades also assist in preventing particles from clogging the exterior side of the polyurethane screen, such as by carbon and pulp. The pulse and sweeping action reduces the possibility of carbon and near size material blinding the screen openings. Impeller blades located on the inside of the screen, such as on the drive shaft, serve to keep particles in suspension and drive pulp upward toward the volute and launder.

During the process, pulp flows upward through the inside of the screen basket <NUM>. Carbon is retained in the screen. The pulp exists via the launder interface situated above the polyurethane screen and volute interface.

In these processes, it can be seen that the continuous rotation of interior and exterior blades in the vicinity of the polyurethane screen, together with the flow of large volumes of pulp through the openings of the polyurethane screen, subjects the screen to substantial wear and tear. The polyurethane screens and the arrangement of the screen basket described herein are designed to withstand significant wear and tear and to substantially outperform existing wire screen baskets in CIP and CIL processes.

Although the screen basket <NUM> has been described for use in a CIP or CIL process, the relatively small openings and relatively large screening area of the polyurethane screen members <NUM> described herein allow the screen basket <NUM> to be used for other purposes, such as water filtration and desalination.

<FIG> illustrates a perspective view of an example of a basket cage <NUM> in accordance with an additional embodiment of the disclosure. The basket cage <NUM> includes a grid frame <NUM> that is tubular (or has substantially cylindrical symmetry) with respect to a longitudinal axis and has multiple openings <NUM>. As such, the grid frame <NUM> has a height and a diameter. As an illustration, the height can have a magnitude in a range from about <NUM> in (about <NUM>) to about <NUM> in (about <NUM>). As another illustration, the diameter can have a magnitude in a range from about <NUM> in (about <NUM>) to about <NUM> in (about <NUM>). In an example embodiment, the height has a magnitude of about <NUM> in (about <NUM>) and the diameter has a magnitude of about <NUM> in (about <NUM>). It is noted that the disclosure is not limited to such illustrative magnitudes of height and/or diameter, and other sizes of the grid frame <NUM> can be contemplated. Additionally, the grid frame <NUM> is not limited to a tubular or cylindrical symmetry, but can be shaped in any configuration suitable for screening, and particularly for carbon retention screening as discussed herein. Grid frame <NUM> may also be formed from any material providing sufficient structure for the screening process and sufficient support for the screening cartridges that will be attached to the grid frame <NUM>. For example, grid frame <NUM> may be formed of a metal or metallic alloy, such as stainless steel, or may be a thermoplastic material sufficient to support the screening cartridges. In embodiments featuring a thermoplastic grid frame <NUM>, the grid frame <NUM> may comprise a single injection-molded piece. In other embodiments, the grid frame <NUM> may be formed of separable pieces connected together to form the grid frame <NUM>.

In certain embodiments, the grid frame <NUM> can be formed in the desired shape by bending a perforated sheet onto itself, around the longitudinal axis, and joining opposing edges of the perforated sheet. The joined opposing edges can form a longitudinal seam <NUM>. In some embodiments, the perforated sheet can be formed from a metal or metallic alloy (e.g., stainless steel), and the opposing edges can be joined by welding. In other embodiments, the perforated sheet can be formed from a rigid plastic, and the opposing edges can be joined by laser welding and/or gluing with a suitable adhesive. The multiple openings <NUM> in the grid frame <NUM> can be arranged in a square lattice, and each one (or, in some embodiments, at least some) of the multiple openings <NUM> can have a square shape. Multiple openings <NUM> may have shapes other than a square shape, such as a rectangular shape, an ovular shape, a circular shape, and so forth. Moreover, multiple openings <NUM> are not required to have a consistent shape throughout the grid frame <NUM>. For example, some embodiments may feature alternating rectangular openings of varying sizes to form the overall grid frame <NUM>. In an example embodiment, the multiple openings <NUM> can include <NUM> square openings. A subset of the multiple openings can be defined by longitudinal members <NUM> and transversal members <NUM>. Openings in such a subset may be referred to as inner openings. A second subset of the multiple openings can be defined by longitudinal members <NUM> and transversal segments of a first annular section 1512a of the grid frame <NUM>. Similarly, a third subset of the multiple openings can be defined by longitudinal members <NUM> and transversal segments of a second annular section 1512b of the grid frame <NUM>. The second subset and the third subset of openings can be referred to as outer openings.

The first annular section 1512a and the second annular section 1512b can embody or otherwise can constitute respective opposing end portions of the grid frame <NUM>, along the longitudinal axis. A flange <NUM> can be affixed or otherwise attached to an end of the first annular section 1512a. The flange <NUM> can include multiple first openings <NUM>. The flange <NUM> and first openings <NUM> can permit or otherwise facilitate mounting a plate or another type of cover on the flange <NUM>. In addition or in other embodiments, the flange <NUM> and first openings <NUM> can permit or otherwise facilitate mounting the basket cage <NUM> into a screen separator machine (e.g., an NKM vertically swept interstage apparatus, as shown in <FIG> and <FIG>). In addition, a second flange <NUM> can be affixed or otherwise attached to the second annular section 1512b. The second flange <NUM> can include multiple second openings <NUM>. The flange <NUM> and second openings <NUM> can permit or otherwise facilitate mounting the basket cage <NUM> into a screen separator machine (e.g., an NKM vertically swept interstage apparatus, as shown in <FIG> and <FIG>), and/or affixing an exterior wiper assembly of the screen separator machine (not shown).

As is illustrated in <FIG>, the basket cage <NUM> can also include an opening in a vicinity of the second end of the grid frame <NUM>, near the second flange <NUM>. A pipe member <NUM> can be assembled on the vicinity of the opening. The opening and the pipe member <NUM> can form an outlet that can permit or otherwise facilitate the egress of a slurry from the interior of the basket cage <NUM> when it needs to be drained upon removal.

Similar to other screen baskets of this disclosure, the basket cage <NUM> in combination with screening elements can be utilized in a separation process to separate specific particulate matter from slurry or another type of fluid source. To that end, in one embodiment, screening cartridge assemblies can be mounted to the basket cage <NUM>, where the screening cartridge assemblies can permit or otherwise facilitate the separation of specific particulate matter from the slurry. Specifically, as an illustration, <FIG> presents a perspective view of an example of a screen basket <NUM> that includes multiple screening cartridge assemblies <NUM> in accordance with one or more embodiments of the disclosure. The multiple screening cartridge assemblies include a first screening cartridge assembly 1610a, a second screening cartridge assembly 1610b, and a third screening cartridge assembly 1610c. Each one of the screening cartridge assemblies 1610a, 1610b, 1610c can be mounted or otherwise affixed to a respective group of grid members that define, at least in part, a respective opening of the grid frame <NUM>. Screening cartridge assemblies <NUM> may be removable, such that screening cartridge assemblies may be mounted to basket cage <NUM> and subsequently removed easily from basket cage <NUM> for maintenance or repair, or may be permanently affixed to basket cage <NUM>. For openings in a row about the longitudinal axis of the grid frame <NUM>, a group of grid members that support a first one of the screening cartridge assembles 1610a and 1610b can have a common grid member with another group of grid members that support a second one of the screening cartridge assemblies 1610a and 1610b. More specifically, in one example, the first screening cartridge assembly 1610a can grip or otherwise attach to a first longitudinal member and a second longitudinal member of the grid frame <NUM>. In addition, the second screening unit 1610b can grip or otherwise attach to the second longitudinal member and a third longitudinal member.

In some embodiments, each one of the multiple screening cartridge assemblies mounted or affixed to the grid frame <NUM> includes a screening assembly and a case (or another type of container) configured to receive and hold the screen assembly. In some embodiments, the case can be embodied in a single injection molded piece integrally formed by means of injection molding a polyurethane, a thermoset polymer, or other types of polymers. Example embodiments of the injection molded piece and the process of forming the injection molded piece are discussed in more detail in the disclosures of <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, and the cross-references included therein. The case and screening assembly held therein may be of any shape and structure suitable for mounting to the grid frame. In some embodiments, the case and screening assembly may be substantially rectangular. In other embodiments, the case and screening assembly may have a square shape, or may be of an ovular shape, or may have a triangular shape, or so forth.

As is illustrated in <FIG>, screening cartridge assembly 1610a includes a case 1630a and a screen assembly having three screen units 1640a. It is noted that the disclosure is not limited to three screen units and, in some embodiments, less or additional screen units can be implemented. For a defined size of a screen unit, a larger number of screen units results in a case 1630a with larger dimensions, thus resulting in a larger screening cartridge assembly. Larger screening cartridge assemblies may be utilized in grid frames having larger grid openings.

The case 1630a includes a first opening configured to receive and/or fit the screen assembly within the case 1630a. The case 1630a also includes a second opening that permits exposing a screening surface of the screen assembly to an exterior of the grid frame <NUM>. The screening surface can be embodied in or can include, for example, a substantially seamless and planar surface including multiple screening openings having, for example, a substantially uniform size and/or substantially uniform shape. The multiple screening openings can have rectangular shape, square shape, circular shape, a combination thereof, or the like. In addition, as is illustrated in <FIG>, the case <NUM> also includes ridges 1650a that extend from a first edge of the case 1630a, near the first opening, to an opposing second edge of the case 1630a. The ridges 1650a and respective portions of the case 1630a form respective recesses that permit or otherwise facilitate mounting (e.g., gripping or clipping) the case 1630a to the grid frame <NUM>. Case 1630a may be permanently mounted to the grid frame <NUM> by use of the ridges 1650a and respective portions of the case 1630a, or may be removably mounted to the grid frame <NUM>, such that the case 1630a may be removed as required for maintenance or repair.

Similarly, screening cartridge assembly 1610b includes a case 1630b and a screen assembly having three screen units 1640b. As mentioned, the disclosure is not limited to three screen units and, in some embodiments, less or additional screen units can be implemented. The case 1630b also includes a first opening configured to receive and/or fit the screen assembly within the case 1630b. The case 1630b also includes a second opening that permits exposing a screening surface of the screen assembly to an exterior of the grid frame <NUM>. The screening surface can be embodied in or can include, for example, a substantially seamless and planar surface including multiple screening openings having, for example, a substantially uniform size and/or substantially uniform shape. In addition, as is illustrated in <FIG>, the case 1630b further includes ridges 1650b that extend from a first edge of the case 1630b, near the first openings, to an opposing second edge of the case 1630b. The ridges 1650b and respective portions of the case 1630b can form respective recesses that permit or otherwise facilitate mounting (e.g., gripping or clipping) the case 1630b to the grid frame <NUM>. In regards to the screen assembly contained in the case 1630b, as is further illustrated in <FIG> and <FIG>, each one of the screen units 1640b includes a framework unit having one or more screen elements affixed to a surface of the framework unit, and the screen units 1640b can be mechanically joined or otherwise secured together to form the screen assembly. To that end, each one of the screen units <NUM>, such as is illustrated with reference to 1640b, can include one or more fasteners that can permit or otherwise facilitate fastening a first one of the screen units (e.g., screen unit 1640a) to a second one of the screen units (e.g., 1640b). Regardless of the mechanism for adjoining the screen units 1640b, the respective screen elements of the screen units <NUM> can form the screening surface that can be exposed to slurry in the exterior of the grid frame <NUM>.

In some embodiments, each one (or, in other embodiments, at least one) of the screen elements can be embodied in a single injection molded piece integrally formed by means of injection molding of a thermoplastic material. Example thermoplastic materials and the processes of creating the example thermoplastic materials used as the screen elements in the present disclosure are discussed in detail in the disclosures of <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, and the cross-references included therein.

Screening cartridge assembly 1610c, like screening cartridge assemblies 1610a, 1610b, also includes a case 1630c and screen assembly having three screen units (not depicted in <FIG>). As mentioned, the disclosure is not limited to three screen units and, in some embodiments, less or additional screen units can be implemented. The case 1630c also includes a first opening configured to receive and/or fit the screen assembly within the case 1630c. The case 1630c also includes a second opening that permits or otherwise facilitates exposing a screening surface of the screen assembly to an exterior of the grid frame <NUM>. The screening surface can be embodied in or can include, for example, a substantially seamless and planar surface including multiple screening openings having, for example, a substantially uniform size and/or substantially uniform shape. In addition, as is illustrated in <FIG>, the case 1630c further includes ridges 1650c that extend from a first edge of the case 1630c, near the first opening, to an opposing second edge of the case 1630c. The ridges 1650c and respective portions of the case 1630c form respective recesses that permit or otherwise facilitate mounting (e.g., gripping or clipping) the case 1630c to the grid frame <NUM>. <FIG> illustrates the mechanical coupling of the screening cartridge assembly 1610a and the screening cartridge assembly 1610b to transversal grid members of the grid frame <NUM>. As mentioned, ridges 1650a permit or otherwise facilitate mounting the screening cartridge assembly 1610a to the grid frame <NUM>. Likewise, ridges 1650b permit or otherwise facilitate mounting the screening cartridge assembly 1610b to the grid frame <NUM>.

The screening cartridge assembly 1610a and the screening cartridge assembly 1610b include respective screen assemblies. The screen assembly contained in the cartridge assembly 1610a includes three screen units 1640a in accordance with embodiments described herein. The other screen assembly contained in the cartridge assembly 1610b also includes three screen units in accordance with embodiments described herein. As mentioned, the disclosure is not limited to screen assemblies having three screen units and, in some embodiments, less or additional screen units can be implemented. Screen assemblies having different number of screen units also can be implemented.

In connection with the screen assembly contained in the case 1630c, as is further illustrated in <FIG>, each one of the screen units that constitutes the screen assembly includes a framework unit having a screen element affixed to a surface of the framework unit. The screen units can be mechanically joined or otherwise secured together to form the screen assembly. To that end, in an embodiment, each one of the screen units can include one or more fasteners that can permit or otherwise facilitate fastening a first one of the screen units to a second one of the screen units. Regardless of the mechanism for adjoining the screen units, the respective screen elements of the screen units <NUM> can form the screening surface that can be exposed to the exterior of the grid frame <NUM>.

It is noted that while three screening cartridge assemblies are illustrated in <FIG> and <FIG>, the entirety or substantially the entirety of the grid frame <NUM> of the screen basket <NUM> can be covered for operation in a separation process. As such, in an example embodiment, <NUM> screening cartridge assemblies can be mounted to the respective <NUM> square openings <NUM> in an embodiment of grid frame <NUM>.

<FIG> illustrates a perspective view of an example of a screening cartridge assembly <NUM>, in accordance with one or more embodiments of the present disclosure. The exemplified screening cartridge assembly <NUM> includes a case <NUM> and a screen assembly having three screen units <NUM>. As mentioned, the disclosure is not limited to three screen units and, in some embodiments, less or additional screen units can be implemented. The case <NUM> has a generally arcuate shape, and includes a first opening configured to receive and/or fit the screen assembly within the case <NUM>. The case also includes a first ridge 1820a and a second ridge 1820b. Each one of the ridge 1820a and the ridge 1820b extends from a vicinity of a first, top edge of the case <NUM> to a vicinity of an opposing second, bottom edge of the case <NUM>. In use, the arcuate shape of case <NUM> allow for a substantially consistent distance between the external propulsion blades of the screening apparatus and the screening cartridge assembly, thereby reducing clogging and elongating the life of the screen elements.

Similar to other screening cartridge assemblies of this disclosure, as is illustrated in the top cross-sectional view <NUM> of screening cartridge assembly <NUM> shown in <FIG>, each one of the screen units <NUM> can include two end framework units <NUM> and a single medial framework unit <NUM>, each of the two end framework units <NUM> and the single medial framework unit <NUM> having a screen element <NUM> affixed to a respective surface of the framework units.

The screen units <NUM> can be mechanically joined or otherwise secured together to form the screen assembly. To that end, in an embodiment, each one of the screen units <NUM> can include one or more fasteners that can permit or otherwise facilitate fastening a first one of the screen units <NUM> to a second one of the screen units <NUM>. Regardless of the mechanism for adjoining the screen units, the respective screen elements of the screen units <NUM> can form a screening surface of the screening cartridge assembly <NUM>. The case <NUM> also includes an opening that permits exposing at least a portion of the screening surface, as is shown in the side view <NUM> of screening cartridge assembly <NUM> in <FIG>.

As is illustrated in the cross-sectional views <NUM> and <NUM> shown in <FIG>, the case <NUM> can include an attachment frame section <NUM> and a holder frame section <NUM>. The attachment frame section <NUM> and the holder frame section <NUM> are also illustrated in the perspective view of the case <NUM> shown in <FIG>. The holder frame section <NUM> can receive and/or hold the screen assembly formed by screen units <NUM>. To that end, in some embodiments, the holder frame section <NUM> includes an opening <NUM>, and internal sidewalls including sidewall <NUM>, sidewall <NUM>, and sidewall <NUM>. Other internal sidewalls are not visible in the perspective view of <FIG>. For instance, as is shown in the cross-sectional view <NUM> of case <NUM> shown in <FIG>, a sidewall <NUM> opposite the sidewall <NUM> and a sidewall <NUM> opposite the sidewall <NUM> also are included in the internal sidewalls of the holder frame section <NUM>. The sidewall <NUM>, in connection with sidewalls <NUM> and <NUM>, can define a first opening, and the opposing sidewall <NUM>, in connection with sidewalls <NUM> and <NUM>, can define a second opening. The second opening can have a cross-sectional area greater than the cross-sectional area of the first opening in order to mitigate undesired reduction of screening area. The smaller cross-section can provide greater mechanical stability for a screen assembly arranged within the case <NUM>. The first opening and the second opening can permit the flow of particulate matter from the exterior to the interior of a screening cartridge assembly including the case <NUM>. The particulate matter can be screened or otherwise separated by such a screen assembly. Specifically, the particulate matter can be separated from slurry external to a screen basket apparatus having a screening cartridge assembly including the screen assembly, and can flow to an internal region of the screen basket apparatus as intended or required for the screening application (e.g., CIL process, CIP process, ore treatment, water desalinization, or the like).

As is further illustrated in cross-sectional views <NUM> and <NUM> in <FIG> and <FIG>, respectively, the holder frame section <NUM> can include a ridge <NUM> near the opening configured to receive a screen assembly, and a ridge <NUM> near a base of the case <NUM>.

In addition, with further reference to <FIG>, the attachment frame section <NUM> includes internal sidewalls, including sidewall <NUM> and sidewall <NUM>, as well as other sidewalls respectively opposite thereto. One of such opposing sidewalls can be gleaned in the side view <NUM> in <FIG>. Specifically, sidewall <NUM> is opposite sidewall <NUM>. The attachment frame section <NUM> also includes the ridge 1820a and the ridge 1820b. In one embodiment, the ridge 1820a and the ridge 1820b and respective portions of the attachment frame section <NUM> form respective recesses <NUM>. Such recesses, as mentioned, can permit or otherwise facilitate mounting (e.g., clipping, clutching, or otherwise engaging) the screening cartridge assembly <NUM> to a grid frame of this disclosure, such as grid frame <NUM> disclosed hereinbefore. As an illustration, <FIG> presents four cases <NUM> mounted adjacent to each one another on a grid frame <NUM>. Respective four screen assemblies can be inserted or otherwise fitted into the four cases <NUM> in order to form four screening cartridges and assemble a screen basket for numerous separation processes, such as CIL process, CIP process, water filtration and desalinization, and the like.

<FIG> illustrates an example of a screen assembly <NUM> in accordance with one or more embodiments of the disclosure. The exemplified screen assembly <NUM> can be arranged or otherwise fitted within a case <NUM> or any other case described herein in order to form a screening cartridge assembly in accordance with this disclosure. Consistent with other screen assemblies disclosed herein, the screen assembly <NUM> includes three framework units, which may include two end framework units <NUM> and a single medial framework unit <NUM>, each of the end framework units <NUM> and medial framework unit <NUM> including screen elements <NUM> affixed thereto. The disclosure is not limited to three framework units <NUM>, <NUM> and/or a specific number of screen elements <NUM> per framework unit <NUM>, <NUM>. In some embodiments, two screen elements <NUM> may be affixed thereto to each of three framework units <NUM>, <NUM>. In some embodiments, less or additional framework units <NUM>, <NUM> and/or screen elements <NUM> can be implemented. Each one (or, in some embodiments, at least one) of the framework units <NUM>, <NUM> can be embodied in a single injection molded piece integrally formed by means of injection molding of a polymer. The framework units <NUM>, <NUM> can be mechanically joined or otherwise secured together to form the screen assembly <NUM>. To that end, in an embodiment, each one of the framework units <NUM>, <NUM> can include one or more fasteners that can permit or otherwise facilitate fastening a first one of the framework units <NUM>, <NUM> to a second one of the framework units <NUM>, <NUM>. Regardless of the mechanism that is utilized or otherwise relied upon to join framework units, the joined framework units <NUM>, <NUM> form a first segmented edge member and an opposing second segmented edge member (not visible in <FIG>). The joined framework units <NUM>, <NUM> also includes a first monolithic edge member and a second monolithic edge member (not visible in <FIG>) corresponding, respectively, to edge members of the outer framework units <NUM>, <NUM>.

Screen elements <NUM> affixed to each one of the framework units <NUM>, <NUM> can form a screening surface of the screen assembly <NUM> and a screening cartridge assembly that includes the screen assembly <NUM>. The screening surface can be essentially seamless, as is illustrated in cross-sectional views <NUM> and <NUM> of screen assembly <NUM> in <FIG>. In some embodiments, as is illustrated in the side view <NUM> of screen assembly <NUM> in <FIG>, each one (or, in other embodiments, at least one) of the screen elements <NUM> can include four adjacent sections having respective groups of screening openings. Such sections may be separated by support members (represented with dashed lines in the plan view <NUM>). The disclosure is not limited to screen elements having four sections and, in some embodiments, less or additional sections having screening openings can be implemented.

<FIG> illustrates a perspective view of medial framework unit <NUM> in accordance with one or more embodiments of the disclosure. The medial framework unit <NUM> is elongated, and includes longitudinal side members <NUM> opposite and substantially parallel to one another. The medial framework unit <NUM> also includes transversal side members <NUM> opposite and substantially parallel to one another. Each one of the transversal side member <NUM> is substantially perpendicular to the longitudinal side members <NUM>. As mentioned, the medial framework unit <NUM> can include fastening mechanisms that permit or otherwise facilitate mechanically joining or otherwise securing together the medial framework unit <NUM> and another framework unit (either an end framework unit <NUM> or a medial framework unit <NUM>). Specifically, in some embodiments, the fastening mechanisms can be assembled or otherwise formed on respective portions of the longitudinal side members <NUM>, with the transversal side members <NUM> free from fastening mechanisms. As is illustrated in <FIG>, in at least one of such embodiments, the fastening mechanisms can be embodied in or can include clips <NUM> and clip apertures <NUM>. The medial framework unit <NUM> and another framework unit (e.g., end framework unit <NUM>) also having clips <NUM> and clip apertures <NUM> can be mechanically joined or otherwise secured together along their respective longitudinal side members <NUM>. To that end, in one embodiment, a clip <NUM> of the medial framework unit <NUM> can be passed into a clip aperture <NUM> of the other framework unit until extended members of the clip <NUM> extend beyond the clip aperture <NUM> and a longitudinal side member of the other framework unit. As the clip <NUM> is pushed into the clip aperture <NUM>, extended members of the clip <NUM> can be forced together until a clipping portion of each extended member is beyond the longitudinal side member of the other framework unit, allowing the clipping portions to engage an interior portion of the longitudinal side member of the other framework unit. When the clipping portions are engaged into the clip aperture <NUM>, longitudinal side members of two independent framework units can be side by side and secured together (e.g., mechanically joined). The framework units can be separated by applying a force to the extended members of the clips such that the extended members are moved towards each other allowing for the clipping portions to pass out of the clip aperture <NUM>. Although the fasteners described herein and shown in drawings are clips and clip apertures, the disclosure is not limited in that respect and alternative fasteners and alternative forms of clips and/or apertures can be used, including other mechanical arrangements, adhesives, etc..

The medial framework unit <NUM> also includes longitudinal support members <NUM> and transversal support members <NUM>. Each one of the longitudinal support members <NUM> is substantially parallel to longitudinal side members <NUM> and is substantially perpendicular to the transversal side members <NUM>. Each one of the transversal support member <NUM> is substantially parallel to transversal side members <NUM> and is substantially perpendicular to the longitudinal support members <NUM>. The longitudinal support members <NUM> and transversal support members <NUM> define, at least in part, multiple grid openings within the medial framework unit <NUM>. In addition, the longitudinal support members <NUM> and the transversal support members <NUM> can provide mechanical stability to a screen element that is affixed to the medial framework unit <NUM>.

The medial framework unit <NUM> also can include second transversal support members <NUM> substantially perpendicular to the longitudinal side members <NUM>. As is illustrated in <FIG> and the side view <NUM> in <FIG>, the second transversal support members <NUM> can be distributed across the grid openings in the medial framework unit <NUM>. The second transversal support members <NUM> can provide further mechanical stability to the screen element that is affixed to the medial framework unit <NUM>.

In order to permit or otherwise facilitate affixing one or more screen elements to the medial framework unit <NUM>, attachment members <NUM> and several adhesion arrangements are included in the medial framework unit <NUM>. As is illustrated in side view <NUM> of medial framework unit <NUM> shown in <FIG>, a first adhesion arrangement includes multiple fusion bars <NUM> assembled (e.g., formed) on surfaces of the longitudinal side members <NUM>. As is shown in the top view <NUM> of medial framework unit <NUM> of <FIG>, a second adhesion arrangement includes multiple fusion bars <NUM> assembled (e.g., formed) on surfaces of the transversal side members <NUM> and transversal support members <NUM>. As is shown in the side view <NUM> of medial framework unit <NUM> of <FIG>, a third adhesion arrangement includes multiple fusion bars <NUM>. In some embodiments, fusion bars <NUM> can have a height that is less than a height of the fusion bars <NUM>, and also less than a height of the fusion bars <NUM>.

In some embodiments, the attachment members <NUM> can permit or otherwise facilitate aligning a screen element for laser welding to the medial framework unit <NUM> or another type of framework unit disclosed herein. The attachment members <NUM> and/or the various fusion bars can be melted during laser welding.

End framework units <NUM> can have similar structure to that of a medial framework unit <NUM>. Fastening mechanisms in an end framework unit <NUM> can be included in a single longitudinal side member of the framework unit <NUM>.

In some embodiments, a screen element can be embodied in or can include the screen element <NUM> as is illustrated in <FIG>. The screen element <NUM> includes first side portions <NUM> and second side portions <NUM> that form a seamless periphery. The first side portions <NUM> are substantially parallel to one another, and each one of the first side portions <NUM> is substantially perpendicular to the second side portions <NUM>. Similarly, the second side portions <NUM> are substantially parallel to one another, and each one of the second side portions <NUM> is substantially perpendicular to the first side portions <NUM>. Each one of the side portions <NUM> is configured to rest on and be affixed to transversal side members (e.g., members <NUM>) of a framework unit <NUM>, <NUM> (e.g., medial framework unit <NUM>) in accordance with embodiments of this disclosure. As such, each one of the side portions <NUM> can include cavities configured to receive or otherwise engage fusion bars on a surface of the transversal side members. Similarly, side portions <NUM> are configured to rest on longitudinal side members of a framework unit <NUM>, <NUM> (e.g., framework unit <NUM>) in accordance with this disclosure. Thus, each one of the side portions <NUM> includes cavities configured to receive or otherwise engage fusion bars on a respective surface of the longitudinal side members.

The screen element <NUM> also includes several support members. More specifically, the screen element <NUM> includes support members <NUM> and support members <NUM>. Support members <NUM> are substantially collinear and substantially perpendicular to support members <NUM>. Support members <NUM> also are substantially collinear. The screen element <NUM> also includes supports members <NUM> that extend from a first one of the side portions <NUM> to a second one of the second side portions <NUM>. Each one of the support members <NUM>, <NUM>, and <NUM> are configured to rest on or be affixed to respective support members of a framework unit <NUM>, <NUM>, such as medial framework unit <NUM>. Thus, each one of the support members <NUM>, <NUM>, and <NUM> includes cavities configured to receive or otherwise engage fusion bars on a respective surface of support members of the framework unit.

The screen element <NUM> further includes attachment apertures <NUM>. One of the attachment apertures <NUM> is positioned essentially at the center of the screen element <NUM>. Other attachment apertures <NUM> are positioned at respective corners of the seamless periphery of the screen element <NUM>. Regardless of position in the screen element <NUM>, each one (or, in some embodiments, at least one) of the attachment apertures <NUM> is configured to permit or otherwise facilitate passage of an elongated attachment member <NUM> (e.g., <FIG>) can pass through the attachment aperture <NUM>. In one or more of such embodiments, the attachment apertures <NUM> may include a tapered bore that may be filled when a portion of the elongated attachment member <NUM> above a screening surface of the screen element <NUM> is melted, fastening screen element <NUM> to the medial framework unit <NUM> or to another type of framework unit disclosed herein. In other embodiments, the attachment apertures <NUM> can be configured without a tapered bore, permitting formation of a bead on a screening surface <NUM> of the screen element <NUM> when a portion of an elongated attachment member <NUM> above such a screening surface is melted, fastening the screen element <NUM> to the medial framework unit <NUM> or to another type of framework unit disclosed herein. The screen element <NUM> can cover a half portion of the medial framework unit <NUM> (or another type of framework unit disclosed herein), and each one of the four sections included in the screen element <NUM> can respectively cover four grid openings of the medial framework unit <NUM>.

The screening surface <NUM> has multiple screening openings. Each one (or, in some embodiments, at least some) of the multiple screening opening can be elongated and can have a defined length and defined width having respective magnitudes based on the screening application (e.g., CIL process, CIP process, ore treatment, water desalinization, or the like) in which the screen element <NUM> is utilized. In some embodiments, the multiple screening openings can have a same substantially uniform length having a magnitude in a range from about <NUM> to <NUM>. In addition, the multiple screening openings can have a same substantially uniform width having a magnitude in a range from about <NUM> to about <NUM>. As an illustration, in some embodiments, the magnitude of width can be approximately equal to one of <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> (<NUM>). In an example embodiment, the multiple screening openings can have a substantially uniform length having a magnitude of about <NUM>. As is illustrated in <FIG> and <FIG> (depicting top and side views <NUM>, <NUM>, and <NUM> of screen element <NUM>), the multiple openings can be arranged in sections, with screening openings in a section arranged in a lattice. Each one of the sections is defined, at least in part, by support members <NUM>, <NUM>, and <NUM> of the screen element <NUM>. In one embodiment, screening openings that are adjacent to a periphery of the screen element <NUM> can be defined by longitudinal bars parallel to first side portions of the screen element <NUM>, transversal bars perpendicular to the longitudinal bars, and segments of edges of side portions of the screen element <NUM>. In addition, screen openings that are in the interior portion of a section can be defined by longitudinal bars and transversal bars. Longitudinal bars define a major side of the elongated openings, and transversal bars define a minor side of elongated openings.

As is illustrated in <FIG> and <FIG>, some embodiments may include fastening mechanisms in framework units (either medial framework units <NUM> or end framework units <NUM>) that can permit or otherwise facilitate assembling a screen assembly <NUM> that has certain curvature. In one of such embodiments, the fastening mechanisms can include clips and clip apertures such that the screen assembly <NUM> that is assembled is curved rather than substantially planar, as shown in the side views <NUM>, <NUM>, and <NUM> of curved screen assembly <NUM> shown in <FIG>.

<FIG> and <FIG> illustrate an alternative embodiment of a cartridge assembly <NUM> for use in a screening basket of the disclosure. Cartridge assembly <NUM> includes a detachable case with top case portion <NUM> and a separate bottom case portion <NUM>. Top case portion <NUM> and bottom case portion <NUM> each include attachment mechanisms <NUM> that may be detachably engaged with apertures <NUM> featured on the top case portion <NUM> and bottom case portion <NUM>. In use, screen assembly having screen units <NUM> may be fitted into a top or bottom case portion <NUM>, <NUM>, and the opposing case portion may then be fitted around the screen assembly with screening units <NUM>. Attachment mechanisms <NUM> engage the apertures <NUM>, securing the screen assembly with screening units <NUM> securely within the case.

Detachable case with top case portion <NUM> and bottom case portion <NUM> includes substantially the same features as case <NUM> discussed herein, including an attachment frame section, holder frame section, and ridges. As shown in the perspective view of bottom case portion <NUM> illustrated in <FIG>, attachment frame section <NUM> includes internal sidewalls and attachment ridges 2420a and 2420b permit or otherwise facilitate mounting (e.g., clipping, clutching, or otherwise engaging) the screening cartridge assembly <NUM> to a grid frame of this disclosure, such as grid frame <NUM>. Holder frame section <NUM> can receive and/or hold the screen assembly formed by screen units, in a manner substantially similar to that of holder frame section <NUM> of case <NUM> discussed in more detail herein.

Top case portion <NUM> and bottom case portion <NUM> may each be formed of a single injection molded piece integrally formed by means of injection molding a polyurethane, a thermoset polymer, or other types of polymer. Due to the relative simplicity of separate top case portion <NUM> and bottom case portion <NUM>, as related to a single case (such as case <NUM>), the top case portion <NUM> and bottom case portion <NUM> may more easily be created by an injection-molding process. Example embodiments of the injection molded process are discussed in more detail in the disclosures of <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, and the cross-references included therein.

Claim 1:
A screen basket apparatus, comprising:
a grid frame (<NUM>) having a plurality of openings (<NUM>) arranged in a lattice, the grid frame (<NUM>) including a plurality of transversal members (<NUM>) and a plurality of longitudinal members (<NUM>) that define the plurality of openings (<NUM>); and
a screen affixed to the grid frame that covers openings (<NUM>) in the grid frame (<NUM>), wherein:
the screen comprises a plurality of screening cartridge assemblies (<NUM>) that includes a first screening cartridge assembly (<NUM>) including a first case (<NUM>) and a first screen assembly fitted into the first case and a second screening cartridge assembly (<NUM>) including a second case (<NUM>) and a second screen assembly fitted into the second case (<NUM>), wherein the first screening cartridge assembly (<NUM>) is affixed to a first transversal member and a second transversal member and wherein the second screening cartridge assembly (<NUM>) is affixed to the second transversal member and a third transversal member,
each screen assembly having a screening surface (<NUM>) and being a single injection molded piece integrally formed by means of injection molding of a thermoplastic material, wherein screening openings are formed in the screening surface (<NUM>), the screening openings having a substantially uniform width having a size that ranges between approximately <NUM> microns and approximately <NUM> microns, and
wherein the screen is configured to separate carbon or resin particles from a slurry of a carbon-in-leach -CIL-, carbon-in-pulp -CIP- or resin-in-leach -RIL- material as fluid of the slurry flows from outside the screen basket apparatus to inside the screen basket apparatus such that the carbon or resin particles remain on the outside of the screen basket apparatus.