Screen element

Abstract

Methods of manufacturing screen elements for use with vibratory separators are disclosed. The screen elements include a curved structural frame with perforations therein, the perforations designed to maximize both open area and process liquid throughput. At least one layer of screen cloth is attached to the curved structural frame by means of fluidized powdered epoxy resin.

1 . A method for producing a laminated screen element comprising the following steps: providing a sheet of thin metal plate; providing at least one layer of screen cloth; providing epoxy; providing a frame forming press; providing a laminating press; perforating the sheet of thin metal plate to produce a screen element frame having inner edges that circumscribe the perforations, and outer edges that circumscribe the screen element frame; curving the screen element frame with the frame forming press to produce a curved screen element frame having inner edges that circumscribe the perforations, and outer edges that circumscribe the curved screen element frame; coating the curved screen element frame with epoxy, thereby producing a coated frame having inner edges that circumscribe the perforations, and outer edges that circumscribe the coated frame; placing the coated frame into the laminating press, and placing the at least one layer of screen cloth over the coated frame in said laminating press; heating the coated frame and the at least one layer of screen cloth placed over the coated frame in the laminating press, thereby producing a laminated screen element.  
   
   
       2 . The method of  claim 1 , wherein the sheet of thin metal plate is flat carbon steel or flat stainless steel.  
   
   
       3 . The method of  claim 1 , wherein the perforating is designed to maximize open area, provide adequate heat capacity for epoxy coating, and provide proper support for the at least one layer of screen cloth.  
   
   
       4 . The method of  claim 1 , wherein the curved screen element frame is cleaned before said coating the curved screen element frame with epoxy.  
   
   
       5 . The method of  claim 4 , wherein said cleaning is by dipping the curved screen element frame into a caustic bath, thereby producing a cleaned frame.  
   
   
       6 . The method of  claim 5 , wherein said cleaned frame is heated to a temperature between 400° F. and 600° F., thereby producing a heated frame, before said coating the curved screen element frame with epoxy.  
   
   
       7 . The method of  claim 6 , wherein said epoxy is a fluidizable powdered epoxy resin.  
   
   
       8 . The method of  claim 7 , wherein said fluidizable powdered epoxy resin is fluidized, and the heated frame is passed through the fluidized powdered epoxy resin, thereby coating the curved screen element frame with epoxy and producing a coated frame.  
   
   
       9 . The method of  claim 8 , wherein said at least one layer of screen cloth is pre-cut to a surface area approximating that of the curved screen element frame.  
   
   
       10 . The method of  claim 9 , wherein said heating the coated frame and the at least one layer of screen cloth placed over the coated frame in the laminating press is at a temperature and for a time sufficient to allow the epoxy to be pushed through the at least one layer of screen cloth, and to cure.  
   
   
       11 . The method of  claim 10 , wherein any of the at least one layer of screen cloth that extends beyond the outer edges of the coated frame is trimmed from said laminated screen element.  
   
   
       12 . A laminated screen element comprising an epoxy-coated screen element frame and at least one layer of screen cloth, wherein the epoxy-coated screen element frame comprises an epoxy coating, a curve, and perforations such that the epoxy-coated screen element frame has inner edges that circumscribe the perforations, and outer edges that circumscribe the screen element frame, and wherein the epoxy-coated screen element frame and the at least one layer of screen cloth are bonded to one another via the epoxy coating.  
   
   
       13 . The laminated screen element of  claim 12 , wherein the epoxy-coated screen element frame is of carbon steel or stainless steel.  
   
   
       14 . The laminated screen element of  claim 13 , wherein the perforations maximize open area, provide adequate heat capacity for the epoxy coating, and provide proper support for the at least one layer of screen cloth.  
   
   
       15 . The laminated screen element of  claim 14 , wherein the epoxy coating is a fluidizable powdered epoxy resin.