Note: Descriptions are shown in the official language in which they were submitted.
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CERAMIC LINED APERTURE SCREENING PANEL
PRIORITY CLAIM
[0001] The present application claims priority to United States
Application Serial No.
17/551,456, filed on December 15, 2021, titled "Ceramic Lined Aperture
Screening Panel",
which claims the benefit of priority of U.S. Provisional Application Serial
No. 63/127,551,
titled "Ceramic Lined Aperture Screening Panel,- filed on December 18, 2020,
both such
applications are incorporated herein by reference
FIELD
[0002] The present disclosure relates generally to screening
systems, or more particularly,
screen panels for use in screening systems.
BACKGROUND
[0003] Screening systems are used in the mining and other
industries to size and separate
desired materials from less desired materials, e.g., by screening particulate
materials. Certain
screening systems are composed of a plurality of modular and replaceable
screening media.
For example, the screening media can include modular screen panels which are
removably
mountable to a support frame to define an overall screening surface. The
screen panels
include a plurality of screening apertures dimensioned to separate the desired
material from
less desired material.
[0004] During a typical screening process, the screening system
is vibrated and the
mixture of particulate material is deposited on the screening surface. The
particulate material
migrates in a preferential feed direction on the screening system, and the
screening apertures
allow smaller material particles to pass through the screening surface while
preventing larger
material particles from passing through the screening surface, thereby
achieving desired
sizing separation of the particulate material.
[0005] Certain screening panels, however, can suffer several
disadvantages. For example,
conventional screen panels are constructed of a frame or insert that is
encapsulated by a
resilient material, such as a polymeric material, such as polyurethane or
rubber. However, the
intense vibrations and abrasive nature of the screening process results in
excessive wear that
can abrade or remove material from the relatively soft polymeric materials.
This wear results
in premature failure of the screen panels and requires frequent monitoring,
maintenance, or
panel replacement. Moreover, as the screen panel wears away over time, the
shape and size of
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the screening apertures in the screen panel changes, resulting in apertures
that are no longer
suitable for their original screening intent. In this regard, wear may
effectively expand the
screening apertures to a size which allows particles that are unacceptably
large to pass
through the screen panel, thus defeating the purpose of material screening
panel and requiring
premature repair or replacement.
[0006] Accordingly, a screening system including screen panels
having improved wear
characteristics would be useful. More specifically, screen panels that are
capable of screening
abrasive materials with reduced wear and long lifetime while maintaining the
designed
aperture geometries for the extended lifetime of the screen panel would be
particularly
beneficial.
SUMMARY
[0007] Aspects and advantages of embodiments of the present
disclosure will be set forth
in part in the following description, or may be learned from the description,
or may be
learned through practice of the embodiments.
[0008] In one example embodiment, a screening system is provided
including a screen
panel at least partially defining a screening surface and an aperture
configured to separate
material and a ceramic aperture insert mounted to the screen panel, the
ceramic aperture
insert at least partially defining the screening surface and the aperture.
[0009] In another example embodiment, a screen system is provided
including a screen
panel defining a plurality of apertures that extend along a vertical direction
through the screen
panel, each of the plurality of apertures being at least partially defined by
an aperture wall of
the screen panel, the screen panel further defining at least one insert recess
defined above the
aperture wall along the vertical direction. One or more ceramic aperture
inserts are positioned
within the at least one insert recess, each of the plurality of apertures
being defined by an
inner face of the one or more ceramic aperture inserts and the aperture wall
of the screen
panel, and wherein a screening surface is defined by atop surface of the
screen panel and a
top face of the one or more ceramic aperture inserts.
[0010] These and other features, aspects and advantages of
various embodiments will
become better understood with reference to the following description and
appended claims.
The accompanying drawings, which are incorporated in and constitute a part of
this
specification, illustrate embodiments of the present disclosure and, together
with the
description, serve to explain the related principles.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Detailed discussion of embodiments directed to one of
ordinary skill in the art are
set forth in the specification, which makes reference to the appended figures.
[0012] FIG. 1 depicts an example screen panel with ceramic
aperture inserts according to
example embodiments of the present disclosure.
[0013[ FIG. 2 depicts a perspective view of a ceramic aperture
insert according to
example embodiments of the present disclosure.
[0014] FIG. 3 depicts a cross-sectional view of a ceramic
aperture insert mounted within
an aperture of a screen panel according to example embodiments of the present
disclosure.
[0015] FIG. 4 depicts a perspective view of a screen panel with
ceramic aperture inserts
according to another example embodiment of the present subject matter.
[0016] FIG. 5 depicts a side, cross-sectional view of the example
screen panel of FIG. 4
according to example embodiments of the present disclosure.
[0017] FIG 6 depicts a close-up, cross-sectional view of the
example ceramic aperture
inserts and screen panel of FIG. 4 according to example embodiments of the
present
disclosure.
[0018] FIG. 7 depicts a perspective view of an insert segment of
the example ceramic
aperture insert of FIG. 4 according to example embodiments of the present
disclosure.
[0019] FIG. 8 depicts a top view of the example ceramic aperture
inserts and screen panel
of FIG. 4 illustrated partially in phantom according to example embodiments of
the present
disclosure.
[0020] FIG. 9 depicts a top view of an example screen panel with
ceramic aperture inserts
according to example embodiments of the present disclosure.
[0021] FIG. 10 depicts a perspective view of an example screen
panel with ceramic
aperture inserts according to example embodiments of the present disclosure.
[0022] FIG. 11 depicts a top view of an example screen panel with
ceramic aperture
inserts according to example embodiments of the present disclosure.
[0023] Repeat use of reference characters in the present
specification and drawings is
intended to represent the same or analogous features or elements of the
present invention.
DETAILED DESCRIPTION
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[0024] Reference now will be made in detail to embodiments, one
or more examples of
which are illustrated in the drawings. Each example is provided by way of
explanation of the
embodiments, not limitation of the present disclosure. In fact, it will be
apparent to those
skilled in the art that various modifications and variations can be made to
the embodiments
without departing from the scope or spirit of the present disclosure. For
instance, features
illustrated or described as part of one embodiment can be used with another
embodiment to
yield a still further embodiment. Thus, it is intended that aspects of the
present disclosure
cover such modifications and variations.
[0025] As used herein, the terms "first,- "second,- and "third-
may be used
interchangeably to distinguish one component from another and are not intended
to signify
location or importance of the individual components. The terms "includes" and
"including"
are intended to be inclusive in a manner similar to the term -comprising."
Similarly, the term
"or- is generally intended to be inclusive (i.e., "A or B- is intended to mean
"A or B or
both"). In addition, here and throughout the specification and claims, range
limitations may
be combined and/or interchanged. Such ranges are identified and include all
the sub-ranges
contained therein unless context or language indicates otherwise. For example,
all ranges
disclosed herein are inclusive of the endpoints, and the endpoints are
independently
combinable with each other. The singular forms -a,- "an,- and -the- include
plural references
unless the context clearly dictates otherwise.
[0026] Approximating language, as used herein throughout the
specification and claims,
may be applied to modify any quantitative representation that could
permissibly vary without
resulting in a change in the basic function to which it is related.
Accordingly, a value
modified by a term or terms, such as "generally," "about," "approximately,"
and
"substantially," are not to be limited to the precise value specified. In at
least some instances,
the approximating language may correspond to the precision of an instrument
for measuring
the value, or the precision of the methods or machines for constructing or
manufacturing the
components and/or systems. For example, the approximating language may refer
to being
within a 10 percent margin, i.e., including values within ten percent greater
or less than the
stated value. In this regard, for example, when used in the context of an
angle or direction,
such terms include within ten degrees greater or less than the stated angle or
direction, e.g.,
-generally vertical" includes forming an angle of up to ten degrees in any
direction, e.g.,
clockwise or counterclockwise, with the vertical direction V.
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[0027] The word "example" is used herein to mean "serving as an
example, instance, or
illustration." In addition, references to -an embodiment" or "one embodiment"
does not
necessarily refer to the same embodiment, although it may. Any implementation
described
herein as -example" or "an embodiment" is not necessarily to be construed as
preferred or
advantageous over other implementations. Moreover, each example is provided by
way of
explanation of the invention, not limitation of the invention. In fact, it
will be apparent to
those skilled in the art that various modifications and variations can be made
in the present
invention without departing from the scope of the invention. For instance,
features illustrated
or described as part of one embodiment can be used with another embodiment to
yield a still
further embodiment. Thus, it is intended that the present invention covers
such modifications
and variations as come within the scope of the appended claims and their
equivalents.
[0028] Referring now generally to FIGS. 1 through 11, aspects of
the present disclosure
will be described according to various example embodiments of the present
subject matter.
For example, aspects of the present disclosure are directed to screening
systems 100 which
may he used in the mining and other industries to size and separate desired
materials from
less desired materials, e.g., by screening aggregate material, particulate
materials, or other
mixtures having various particulate sizes and shapes. For example, screening
system 100 may
generally include support frames and additional systems for transporting
screening materials,
vibrating screening system 100, and performing other actions to facilitate the
screening
process. For brevity, detailed discussion of these components is omitted from
the present
discussion.
[0029] As explained above, certain screening systems are composed
of a plurality of
modular and replaceable screening media. For example, aspects of the present
subject matter
are generally directed to screen panels 102 for used in screening systems,
such as screening
system 100, for screening materials. These screen panels 102 may be modular
and may be
removably mounted to the support frame of screening system 100 to define an
overall
screening surface (e.g., identified generally herein by reference numeral
104). Each screen
panel 102 may generally include or define a plurality of screening apertures
106 that are
dimensioned for a particular application in order to separate desired
materials from less
desired materials.
[0030] During a typical screening process, screening system 100
vibrates one or more of
screen panels 102 while a mixture of particulate material is deposited on
screening surface
104. The mixture of particulate material may migrate in a preferential feed
direction on the
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screening surface 104, and screening apertures 106 may allow smaller material
particles to
pass through screening surface 104 while preventing larger material particles
from passing
through screening surface 104, thereby achieving desired sizing separation of
the mixture of
particulate material.
[0031] Increased wear life of screening media (e.g., such as
screen panel 102) used to sort
particle size in mining, aggregate, and other material processing applications
is always
desirable. The abrasive nature of the screening process encourages use of
screen media made
from materials that are highly resistant to abrasion wear. Over time, as the
media wears away,
the shape and size of the apertures in the media material changes resulting in
undesirable
variation in the size of particles passing through the screen media. Practical
applications
require a balance among the cost of the screen media, the wear rate of the
screen media, and a
tolerable amount of particle size variation for material passing through the
screen media.
[0032] Accordingly, to address the various issues set forth
above, aspects of the present
subject matter are generally directed to screen panels 102 with improved
abrasion and wear
resistance. More specifically, screen panels 102 described herein are
particularly suited to
reduce wear from interaction with mixtures of aggregate screening materials,
generally
resulting in a longer panel lifetime and better screening performance. In
addition, each of the
screen panels 102 described herein includes features for reducing wear,
particularly around
the apertures 106 that are used to screen the material mixtures. Notably,
improved abrasion
and wear resistance around the apertures may result in improved screening for
the lifetime of
screen panels 102, as the shape and size of the apertures 106 remain
relatively constant.
[0033] Example screen media materials can include steel wire,
stainless steel wire,
rubber, and urethane elastomers. One class of materials noteworthy for their
abrasion
resistance are engineered ceramics. Driven by their inherent hardness,
ceramics offer
unparalleled resistance to abrasive wear and may be used in mining and
aggregate material
handling applications where severe abrasion occurs. Example aspects of the
present
disclosure can utilize the abrasive wear resistance of engineered ceramics to
create screen
media with higher degrees of open area, longer wear life, and more consistent
particle size
outputs. Accordingly, screen panels 102 can include, for instance, one or more
ceramic
aperture inserts (e.g., identified generally by reference numeral 110) that
extend at least
partially around a perimeter of at least one aperture 106 for improve wear
resistance and
panel durability. Various screen panels 102 and configurations of ceramic
aperture inserts
110 will be described herein according to example embodiments of the present
subject
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matter. Due to similarity between embodiments, like reference numerals may be
used to refer
to the same or similar features among embodiments.
[0034] Specifically, referring now briefly to FIGS. 1 through 3,
an example screen panel
102 and ceramic aperture inserts 110 will be described according to example
embodiments of
the present subject matter. As illustrated, screen panel 102 may generally be
a solid or
substantially solid panel with a plurality of apertures 106 that are molded,
punched, or
otherwise formed within screen panel 102. In general, screening system 100 may
rely at least
in part on the force of gravity during the screening process and each screen
panel 102 may
generally define a vertical direction V. a lateral direction L, and a
transverse direction T, each
of which is mutually perpendicular, such that an orthogonal coordinate system
is generally
defined. According to an example embodiment, the vertical direction V of
screen panel 102 is
substantially aligned or parallel to the force of gravity.
[0035] According to an example aspect of the present disclosure,
screen panel 102 may
include a polymer matrix 112 or other suitable support frame for maintaining
the integrity of
apertures 106 even through the intense screening process. In some embodiments,
a
reinforcing structure can be embedded within the polymer matrix 112 or
attached to the
polymer matrix 112 to provide strength and stiffness to the composite
screening panel 102.
The polymer can be of any type such as a rubber or urethane elastomer or
blends of
elastomers or other suitable polymers. For example, the reinforcing structure
can be made of
steel, aluminum, fiber reinforced polymer, or other suitable reinforcing
materials and can be
shaped such that is does not interfere with the positioning of ceramic
aperture inserts 106.
[0036] The polymer matrix 112 surrounding the ceramic aperture
inserts 110 can serve to
bind together the ceramic aperture inserts 110 in predetermined patterns for
optimal screening
performance. For example, the polymer matrix 112 can fill the spaces between
and around
the ceramic aperture inserts 110. In this regard, the polymer matrix 112
serves to separate and
isolate the ceramic aperture inserts 110 and to bond the ceramic aperture
inserts 110 together
forming a modular screen panel 102 with defined dimensions and a well-defined
aperture
pattern. The polymer material can also serve to provide additional features
such as attachment
elements to attach screen panel 102 to a frame system. For example, in some
embodiments,
screen panel 102 can include features for attaching to a support system, such
as one or more
mounting bosses 114 (see, e.g., FIG. 4).
[0037] In some embodiments, screen panel 102 may further include
a structural
reinforcing frame (not shown) or a frame for locating ceramic aperture inserts
106. In some
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embodiments, a ceramic aperture insert positioning frame can be used to create
and maintain
a certain spacing and pattern of the ceramic aperture inserts 110. The
positioning frame can
be made of steel, aluminum, or more preferably polymer, or most preferably
fiber reinforced
polymer composite. The positioning frame can contain features such as tabs or
grooves that
engage with the ceramic aperture inserts 110. The ceramic aperture insert
positioning frame
may be at least partially embedded within the polymer matrix 112.
[0038_1 As illustrated, according to example embodiments, ceramic
aperture inserts 110
can be incorporated into screen panel 102 and may extend around the entire
perimeter of the
apertures 106. Therefore, the aperture size and shapes maybe defined by the
characteristics of
the openings in the ceramic aperture inserts 110. The composite screen panel
102 can have
defined dimensions and one or more ceramic aperture inserts 110 can be
arranged in a
defined pattern configured for improved overall screening process performance.
For example,
as illustrated in FIG. 1, apertures 106 are substantially circular and are
each fitted with
circular ceramic aperture inserts 110.
[0039] As illustrated, ceramic aperture inserts 110 only extend
through a portion of the
height of screen panel 102. For example, ceramic aperture inserts 110 may
define a height
that is less than 1/2, less than 1/4, less than 1/8, or less, than a height of
screen panel 102 as
measured along the vertical direction V. By contrast, according to alternative
embodiments
ceramic aperture inserts 110 may extend to the entire thickness or height of
screen panel 102.
According to exemplary embodiments, the height of ceramic aperture inserts 110
may be
defined relative to the average aperture dimension, e.g., such as the width
measured along the
lateral direction L. For example, the height of ceramic aperture inserts 110
may be less than
1/2 of the aperture width, less than 1/4 of the aperture width, less than 1/8
of the aperture
width, or less. It should be appreciated that the ratio of the insert height
to the aperture size
(e.g., width) and the ratio of the insert height to the height of screen panel
102 may vary
while remaining within the scope of the present subject matter, e.g., based at
least in part on
the tendency or lack of tendency for the rocks or particles to get stuck or
"peg- or "plug" the
apertures 106.
[0040] In some embodiments, the ceramic aperture inserts 110 can
be made of ceramic
material such as alumina, aluminum oxide, zirconia, silicon carbide, tungsten
carbide,
diamond, or blends of such materials chosen for their wear resistance. The
ceramic aperture
insert can define a three-dimensional volume with a shape comprising an upper
surface, a
lower surface and an outer perimeter surface. At least one hollow opening
extends through
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the volume from the upper surface to the lower surface forming an aperture.
Although
example shapes, sizes, geometries, and configurations of ceramic aperture
inserts 110 are
described below to facilitate discussion of aspects of the present subject
matter, it should be
appreciated that these inserts are not intended to be limiting in any manner.
Indeed, variations
and modifications to ceramic aperture inserts 110 may be made while remaining
within the
scope of the present subject matter.
[0041] According to the illustrated embodiment, screen panel 102
may generally define a
screening surface 104 that is a substantially planar surface configured for
receiving the
mixture of particulate material. For example, according to the illustrated
embodiment,
screening surface 104 may be positioned above and opposite a bottom side 122
of screen
panel 102 along the vertical direction V. In general, each aperture 106 may be
defined by an
aperture wall 124 of screen panel 102 and may extend through screen panel 102
substantially
along the vertical direction V. Specifically, aperture 106 may extend from an
aperture inlet
126 which is substantially coplanar with screening surface 104 and an aperture
outlet 128 that
is substantially coplanar with a bottom side 122 of screen panel 102. During
operation,
material that is small enough to fit through aperture 106 may fall under the
force of gravity
through aperture inlet 126, into aperture 106, and out of aperture 106 through
aperture outlet
128.
[0042] In general, ceramic aperture inserts 110 may be embedded
within, seated into, or
mounted to screen panel 102 (e.g., or more particularly within the polymer
matrix 112 of
screen panel 102) in any suitable manner. For example, as best illustrated in
FIGS. 3 and 6,
screen panel 102 may generally define insert recesses 130 that are sized and
configured for
receiving ceramic aperture inserts 110. More specifically, according to the
illustrated
embodiment, insert recesses 130 may be defined above aperture walls 124 and
may be
defined such that screen panel 102 defines a support shoulder 132 that is
positioned below
screening surface 104 along the vertical direction V. such that a bottom face
134 of ceramic
aperture inserts 110 is seated on support shoulder 132. When so positioned,
atop face 136 of
ceramic aperture insert 110 may be flush with screening surface 104 (e.g., may
be coplanar
with screening surface 104). By contrast, according to the illustrated
embodiment, top face
136 of ceramic aperture inserts 110 may extend slightly above screening
surface 104 along
the vertical direction V. According to example embodiments, top face 136 of
ceramic
aperture insert 110 may at least partially define screening surface 104 of
screen panel 102.
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[0043] According to example embodiments ceramic aperture inserts
110 may further
define an inner face 140 that at least partially defines aperture 106. In this
regard, inner face
140 may be directly adjacent and form at least a partial boundary of aperture
106. According
to an example embodiment, inner face 140 of ceramic aperture inserts 110 may
sit
substantially flush with aperture wall 124 of screen panel 102. Moreover,
referring now
briefly to FIGS. 3 and 5, inner face 140 and/or aperture wall 124 may be
tapered to define a
relief angle 142 relative to the vertical direction V. In this manner, for
example, aperture inlet
126 may generally have a smaller cross-sectional area than aperture outlet
128, e.g., such that
relief angle 142 may facilitate the easy exit of particles passing through
screen panel 102.
According to example embodiments, relief angle 142 may be between about 0.5
and 200
,
between about 10 and 100, between about 3 and 50, or about 4 relative to the
vertical
direction V. Although aperture 106 is illustrated as being tapered at a fixed
angle, it should be
appreciated that according to alternative embodiments, aperture 106 may be
stepped or have
any other suitable cross-sectional geometry or profile while remaining within
the scope of the
present subject matter.
[0044] Notably, when ceramic aperture inserts 110 are positioned
within insert recesses
130 of screen panel 102, the polymer matrix 112 of screen panel 102 and the
ceramic
aperture inserts 110 generally define an upper screening surface 104 and
extend substantially
within a horizontal plane (e.g., defined by the lateral direction L and the
transverse direction
T). In addition, the polymer matrix 112 and ceramic aperture inserts 110
collectively define
each aperture 106 and the ceramic aperture inserts 110 may be particularly
suited to prevent
wear or abrasion on the edges surrounding aperture inlet 126, such that the
size, shape, and
geometry of apertures 106 may remain relatively constant over the lifetime of
screen panel
102.
[0045] According to the embodiment illustrated in FIGS. 1 through
3, ceramic aperture
inserts 110 are formed from a single piece and are circular or rectangular in
cross-sectional
profile. In this regard, ceramic aperture inserts 110 may extend around an
entire perimeter of
aperture 106 to form a full enclosure around the aperture 106. However, it
should be
appreciated that the size, shape, and geometry of ceramic aperture inserts 110
may change
while remaining within the scope of the present subject matter. For example,
ceramic
aperture insert shapes can include hollow cylinders, rings, eyelets, squares,
rectangles, or
modifications thereof. Moreover, referring now generally to FIGS. 4 through
11, each
ceramic aperture insert 110 may be formed from a plurality of insert segments
(identified
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herein generally by reference numeral 150) that collectively form the ceramic
aperture insert
110.
[0046] For example, the plurality of insert segments 150 may
generally be positioned
around the perimeter 152 of each aperture 106 such that at least one perimeter
gap 154 is
defined between adjacent segments 150. In this regard, as shown for example in
FIG. 5, the
ceramic aperture insert 110 can include four separate insert segments 150
(e.g., a first
segment, a second segment, a third segment, and a fourth segment) that fit
together to line the
perimeter 152 of the aperture 106. In alternative embodiments, the ceramic
aperture insert
110 can be divided into more or fewer segments 150. For instance, as shown in
FIGS. 9 and
11, the ceramic aperture insert 110 can be divided into six separate segments
150 that fit
together to line the perimeter of the aperture 106. In some implementations,
as shown in the
figures, the different segments 150 of the ceramic aperture insert 110 can be
spaced apart
from one another by perimeter gaps 154 that are defined between adjacent
segments 150.
However, according to alternative embodiments, perimeter gaps 154 may be
eliminated and
adjacent segments 150 may contact or butt directly up to each other.
[0047] The exact configuration of insert segments 150 may vary in
order to achieve
various performance objectives of a particular screen panel 102. Aspects of
the present
subject matter are not restricted to any particular configuration of insert
segments 150
illustrated herein. According to an example embodiment, as best illustrated in
FIGS. 4, 8, 9,
and 11, insert segments 150 may be positioned along one or more edges of the
aperture
profile. More specifically, aperture 106 may have a rectangular profile (e.g.,
as defined within
a horizontal plane or a plane that is coplanar to screening surface 104).
According to the
illustrated embodiment, insert segments 150 may be positioned along the edges
160 of these
rectangular profiles. In addition, perimeter gaps 154 may generally be defined
in the corners
162 of the rectangular profile of apertures 106. According to still other
embodiments,
perimeter gaps 134 may also be defined between multiple insert segments 150
that are
positioned along a single edge 160. By contrast, as best illustrated in FIG.
10, insert segments
150 may be curved or angled at approximately 90 and positioned within corners
162 of
apertures 106. In this manner, perimeter gaps 154 may be defined along edges
160 of
aperture 106, e.g., between the ends of insert segments 150.
[0048] Referring now briefly to FIG. 11, screen panel 102 may
further define one or more
panel extensions 164 that generally protrude into apertures 106. In this
regard, panel
extensions 164 may be the portion of the polymer matrix 112 of screen panel
102 that extend
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into apertures 106 and that serve to form the perimeter gap 154 between
adjacent insert
segments 150. In addition, panel extensions 164 may generally prevent large
particulates
from passing through aperture 106 while permitting some flexibility for
moderate size
particulates. Furthermore, as shown in FIGS. 4 through 11, perimeter gap 154
may generally
be filled with a polymeric material, e.g., a portion of screen panel 102. In
this manner, screen
panel 102 may fill at least one of the perimeter gaps 154 such that inner face
140 of insert
segments 156 substantially flush with aperture wall 124 of screen panel 102.
[0049] In general, it may be desirable to ensure that perimeter
152 of aperture 106 is
largely bounded by insert segments 150. In this regard, it may be desirable to
carefully
control the ratio of perimeter gaps 154 to insert segments 150. For example,
according to
example embodiments, insert segments 150 may form greater than 60%, greater
than 70%,
greater than 80%, greater than 90%, or greater than 95% of the total linear
perimeter 152 of
aperture 106. In addition, it may be desirable to regulate the average gap
length relative to the
length of insert segments 150. In this regard, an average gap length 170 may
be defined as the
linear distance of the perimeter gaps 154 as measured along the perimeter 152
of aperture
106. In addition, an average insert length 172 may be measured as the average
length of insert
segments 150 as measured along the perimeter 152 of aperture 106. In general,
the average
gap length 170 may be less than 1/2 of the average insert length 172, less
than 1/4 of the
average insert length 172, less than 1/8 of the average insert length 172,
less than 1/16 of the
average insert length 172, or less.
[0050] According to example embodiments, screen panel 102 may use
various
mechanisms and features to ensure ceramic aperture inserts 110 are securely
and firmly
embedded within screen panel 102. For example, in some embodiments, the
surfaces of
ceramic aperture inserts may be treated with a bonding agent to facilitate
adhesion to the
polymer matrix 112 of screen panel 102. Bonding agents can include any
suitable material
but, in some embodiments, can be silane based. For example, commercial bonding
agents for
ceramic to rubber bonding may include Chemlok 6411 with Chemlok 144 primer
or
Cilbond 24. For example, for ceramic to urethane bonding, a bonding agent may
include
Chemlok 213 or Cilbond 48 or Cilbond 49SF. Other suitable bonding agents
are
possible and within the scope of the present subject matter.
[0051] According to still other embodiments, screen panel 102 and
ceramic aperture
inserts 110 may define complementary recesses and/or protrusions that are
intended to
provide mechanical interlocking of the two components for securing ceramic
aperture inserts
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110 within the polymer matrix 112 of screen panel 102. For example, as best
illustrated in
FIGS. 6 through 8, screen panel 102 may generally define one or more locking
recesses 180
that are defined around aperture 106 or surrounding insert recesses 130 below
screening
surface 104 along the vertical direction V. In addition, ceramic aperture
inserts 110 may
define one or more complementary protruding features 182 that are generally
configured for
receipt with in the one or more locking recesses 180 to secure ceramic
aperture insert 110
within screen panel 102. In this regard, during the molding process of screen
panel 102,
polymer matrix 112 may flow, form, and cure around complementary protruding
features 180
to provide secure mechanical engagement of ceramic aperture inserts 110 within
screen panel
102.
[0052] Referring now briefly to FIGS. 7 and 8 according to
example embodiments, the
one or more complementary protruding features 182 may be offset from a center
of ceramic
aperture insert 110 or insert segment 150. More specifically, as best shown on
insert segment
150 illustrated in FIG. 7, complementary protruding feature 182 may extend
from an
engaging face 184 of insert segment 150 (e.g., opposite inner face 140 within
a horizontal
plane). Complementary protruding feature 182 may be offset along the elongated
dimension
of engaging face 184. In this manner, as best shown in FIG. 8, insert segments
may be
positioned immediately adjacent each other on adjacent apertures 106 while
minimizing the
space there between, e.g., resulting in a smaller bridge between apertures 106
and better
screening performance. Although the example illustrated embodiment shows
insert segments
150 as defining protruding features 182 and screen panel 102 as defining
locking recesses, it
should be appreciated that these two features could be swapped or alternated
while remaining
within the scope of the present subject matter. Moreover, the number, size,
geometry, and
positioning of such engaging features may vary without departing from the
scope of the
present subject matter.
[00531 In some embodiments, the ceramic aperture insert 110 shape
can include
additional features. For instance, the ceramic aperture insert 110 can include
one or more
bumps, tabs, rings, or lips that extend outward from the outer perimeter
surface to enable
predetermined spacing between adjacent ceramic inserts. In some embodiments,
the ceramic
aperture insert 110 can include one or more bumps, tabs, rings, lips,
indentations, or grooves
extending from the outer perimeter surface to enable mechanical interlocking
with a ceramic
aperture insert positioning frame. In some embodiments, the ceramic aperture
insert can
include one or more bumps, tabs, rings, lips, indentations, or grooves
extending from the
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outer perimeter surface to enable mechanical interlocking with the polymer
matrix 112 of
screen panel 102.
[0054] While the present subject matter has been described in
detail with respect to
specific example embodiments thereof, it will be appreciated that those
skilled in the art,
upon attaining an understanding of the foregoing may readily produce
alterations to,
variations of, and equivalents to such embodiments. Accordingly, the scope of
the present
disclosure is by way of example rather than by way of limitation, and the
subject disclosure
does not preclude inclusion of such modifications, variations and/or additions
to the present
subject matter as would be readily apparent to one of ordinary skill in the
art.
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