United States Patent
`[19]
`[11] Patent Number:
`6,032,806
`
`Leone et al.
`[45] Date of Patent:
`Mar. 7, 2000
`
`USOO6032806A
`
`[75]
`
`[54] SCREEN APPARATUS FOR VIBRATORY
`SEPARATOR
`Inventors: Vincent D. Leone, Houston; Thomas
`.
`C- Adams> H0Ck1€Y>b0th 0f Te’fv
`Jefirey Walker, Lafayette; DaVId L-
`Schulte, Jr-, Broussard, both of La.;
`Charles N. Grichar; Kenneth W.
`
`Seyfi'ert, bOth 0f HOUStOH, Tex.; Guy L-
`McClung, III, Spring, Tex.
`
`.
`[73] Assignee: Tuboscope I/P, Inc.
`
`[21] Appl. No.: 09/276,267
`
`[22]
`
`Filed:
`
`Mar. 25, 1999
`
`FOREIGN PATENT DOCUMENTS
`59—142818 of 1984
`Japan .
`$3223
`4/1928 Untied Kfngdom ””””””””” 8794 27
`of 1939 Un1ted Kingdom .
`823648 of 1957 United Kingdom .
`1412975
`of 1972 United Kingdom .
`2124099A of 1983 United Kingdom .
`
`(List continued on next page.)
`
`OTHER PUBLICATIONS
`
`“Derrick Sandwich Shaker, ” Derrick Equipment Co. (Prior
`to 1992).
`
`“Derrick Pyramid Screens,” Derrick Corp.
`
`Related US. Application Data
`
`(List continued on next page.)
`
`[60] Division of application No. 08/786,515, Jan. 21, 1997,
`which is a continuation—in—part of application No. 08/504,
`495, Jul. 20, 1995, Pat. No. 5,598,930, application No.
`08/598,566, Feb. 12, 1996, abandoned, and application No.
`29/048,575, Jan. 4, 1996, Pat. No. Des. 377,636, which is a
`continuation of application No. 29/014,571, Oct. 25, 1993,
`Pat. .No: Des. 366,040, which is a continuation—in—part of
`88811:?dogplplficzgié:5$8208fi%2,888,1:9113g9Pf2t, 1119939315323?
`No. 5,392,925, said application No. 08/598,566, is a con—
`tinuation-in—part of application No. 08/220,101, Mar. 30,
`1994, Pat NO- 59490598
`Int. Cl.7 ........................................................ B07B 1/49
`[51]
`[52] US. Cl.
`........................... 209/402; 209/403; 209/412
`58
`F' ld f S
`h
`209 311 315
`[
`]
`1e
`0
`earzcog 319329331333399 /405’ 273’
`/
`’
`’
`’ 292’ 391’ 402’ 412’
`’
`’
`’
`
`[56]
`
`_
`References Clted
`U.S. PATENT DOCUMENTS
`
`9/1995 Ray ........................................... 428/98
`H1481
`40,242 10/1863 Capell .
`236,416
`1/1881 Bourne .
`246,144
`8/1881 Keeler .
`268,491
`12/1882 Hubbell .
`275,190
`4/1883 Gilbert .
`
`.
`.
`Prlmary Examiner—Donald P- waISh
`Assistant Examiner—Daniel Schlak
`Attorney Agent or Firm—Guy MCClung
`’
`’
`
`ABSTRACT
`[57]
`Ascreen is disclosed which, in certain aspects, has screening
`materlal between opposed frame Sldes and one or more
`lower strips beneath the screen. In one aspect these strips are
`only inteconnected Via their ends and not along their lengths.
`In certain aspects, a plurality 0f lower strips are bonded to
`the screen and extend across the screen from one frame Slde
`to the other. In one aspect one or more of the strips has one,
`two, or more humps or ridges corresponding to one or more
`corrugations in a corrugated perforated plate and/or corru-
`gated screen assembly which is on the plate or, with no plate
`present, on the strips. In another aspect instead of the strips
`a solid corrugated perforated plate is used. In one aspect
`openings or perforations through the plate are triangular. In
`one aspect the screen is undulating screening material and
`lower portions of the screening material are bonded to a
`plate or to strips. Optionally screen mounting hooks or frame
`edges or screen edges may be used with such screens. A
`screening apparatus or shale shaker is disclosed which uses
`such plates and screens.
`
`(List continued on next page.)
`
`20 Claims, 28 Drawing Sheets
`
`
`
`|PR2018—00015
`Petitioners Ex. 1008 p. 1
`
`IPR2018-00015
`Petitioners Ex. 1008 p. 1
`
`

`

`6,032,806
`
`Page 2
`
`..................... 209/401 X
`
`.
`
`.
`
`.
`
`US. PATENT DOCUMENTS
`.
`4/1883 Kimball -
`2757340
`6/1893 Stf>e°ket 6t a1~ -
`5007302
`3/1894 W115“ -
`5167673
`9/1894 CIPSS -
`5267562
`5/1896 Mlssroon -
`5607858
`6/1897 Plaisted -
`583981
`7/1898 Closz .
`607,598
`777,317 12/1904 Traylor .
`865,185
`9/1907 Kerrigan .
`948,222
`2/1910 Honabach .
`964,897
`7/1910 Bryant .
`966,578
`8/1910 Murphy et al.
`984,866
`2/1911 Tate .
`1,098,979
`6/1914 Schuchard.
`1,132,667
`3/1915 Milliot .
`1,139,041
`5/1915 Larson.
`1,242,982 10/1917 Reynolds .
`1,248,081
`11/1917 Couch .
`1,250,768 12/1917 Baumgartner ........................... 209/392
`1,344,747
`6/1920 Wright .
`1,397,339
`11/1921 Sturtevant .
`1,423,021
`7/1922 Reynolds .
`1,462,804
`7/1923 Evans .
`1,505,735
`8/1924 Stebbins .
`1,561,632
`11/1925 Woodward .
`1,614,586
`10/1927 Anderson et al.
`1,626,774
`5/1927 Allan .
`1,678,941
`7/1928 Helman .
`1,713,143
`5/1929 Overstrom .
`1,716,758
`6/1929 Bland.
`1,785,195
`12/1930 Hoes et al.
`1,879,377
`9/1932 McNeely .
`1,950,861
`3/1934 O’Toole, Sr.
`1,997,713
`4/1935 Boehm .
`1,997,740
`4/1935 Nickerson .
`2,052,467
`8/1936 Hermann ................................. 209/401
`2,061,850
`11/1936 Roberts .
`2,082,513
`6/1937 Roberts .
`.
`2,089,548
`8/1937 Frantz et al.
`2,104,785
`1/1938 Akeyson ................................. 210/384
`2,190,262
`2/1940 Geist .
`2,251,909
`8/1941 Lindsay ................................... 210/149
`2,274,700
`3/1942 Jenks .
`2,335,084
`11/1943 Rice ........................................ 209/408
`2,406,051
`8/1946 Weiss .
`2,462,878
`3/1949 Logue .
`2,480,320
`8/1949 Carrier .................................... 210/388
`2,511,239
`6/1950 Behnke et a1.
`.......................... 209/403
`2,648,441
`8/1953 Soldan .
`2,667,975
`2/1954 Seaholm .................................. 210/152
`2/1954 Betts ....................................... 209/405
`2,670,079
`
`5/1954 Conkling .............................. 209/403
`2,677,462
`2,723,032
`11/1955 Gisler et a1.
`.
`2,726,184 12/1955 Cox et al.
`.
`2,774,477 12/1956 Pollitz ..................................... 209/403
`
`. 209/412 X
`2,800,227
`7/1957 Kiger
`
`11/1957 Brugmann ............................... 209/403
`2,813,629
`2,827,169
`3/1958 Cusi .
`2,902,165
`9/1959 Imershein .
`2,929,464
`3/1960 Sprouse .
`2,973,865
`3/1961 Cibula ..................................... 209/315
`2,980,208
`4/1961 Neumann .
`279857303
`5/1961 anht ~
`3,057,481
`10/1962 Pale ......................................... 210/493
`12/1962 McCorkel et al.
`.. 209/319
`3,070,231
`
`.. 209/403
`..
`3,092,573
`6/1963 Lambert et al.
`
`.......
`.. 210/510
`3,165,473
`1/1965 Pall et a1.
`.. 209/403
`4/1965 Hoskins et al.
`3,176,843
`
`3,243,943
`4/1966 Getzin ........
`55/499
`6/1966 Burls ....................................... 209/314
`3,255,885
`
`3,285,413
`11/1966 Taylor—Smith .
`3,458,978
`8/1969 DaVis ........................................ 55/499
`3,465,413
`9/1969 Rosaen et al.
`........................... 29/428
`
`3,542,636
`11/1970 Wandel
`. 161/114
`3,574,103
`4/1971 Latkin ....................................... 428/72
`3,655,060
`4/1972 Hagdahl
`.................................. 210/493
`
`3,679,057
`. 210/223
`7/1972 Perez
`3,716,138
`2/1973 Lumsden ..
`. 209/401
`
`3,747,770
`. 210/402
`7/1973 Zentis
`
`3,747,772
`. 210/493
`7/1973 Brown
`3,789,498
`2/1974 Cole .....
`29/470.9
`
`3,793,692
`2/1974 Tate et al.
`29/163.5
`
`3,853,529
`12/1974 Boothe et al.
`............................ 55/499
`3,900,628
`8/1975 Stewart .
`4,019,987
`4/1977 Krashow ................................. 210/232
`4,022,596
`5/1977 Pedersen ..
`55/528
`
`4,033,865
`.
`. 209/275
`7/1977 Derrick, Jr.
`
`4,062,769
`12/1977 Simonson
`. 209/399
`
`4,075,106
`. 210/487
`2/1978 Yamazaki .
`4,138,303
`2/1979 Taylor ..
`. 156/264
`
`4,380,494
`. 209/319
`4/1983 Wilson .
`
`4,410,427 10/1983 Wydeven .
`. 210/317
`. 204/253
`4,464,242
`8/1984 Boulton
`9/1984 DaVis et al.
`. 428/184
`4,472,473
`
`10/1985 Lott .............
`4,546,783
`. 134/109
`
`. 209/397
`4,575,421
`3/1986 Derrick et al.
`
`4,582,597
`4/1986 Huber ..........
`. 204/313
`
`5/1986 Wydeven .
`4,589,983
`210/317
`
`. 210/493.3
`4,617,122 10/1986 Kruse et al
`4,634,535
`1/1987 Lott ..........
`210/780
`4,678,578
`7/1987 Nodes et al.
`. 210/445
`
`. 210/780
`4,696,751
`9/1987 Eifling ..
`
`. 210/314
`4,728,422
`3/1988 Bailey ..
`9/1988 DaVis et al.
`4,769,968
`52/814
`
`. 209/397
`4,820,407
`4/1989 Lilie .....
`
`. 209/397
`4,832,834
`5/1989 Baird, Jr.
`8/1989 Derrick et al.
`. 209/392
`4,857,176
`
`4,882,054 11/1989 Derrick et al.
`.....
`. 210/389
`
`
`. 156/204
`4,940,500
`7/1990 Tado Koro et al.
`.............................. 209/273
`4,954,249
`9/1990 Gero et al.
`5,028,474
`7/1991 Czaplicki
`................................ 428/178
`
`5,084,178
`1/1992 Miller et al.
`. 210/493.5
`8/1992 Souter ..................................... 209/403
`5,137,622
`5,139,154
`8/1992 Gero et al.
`.............................. 209/273
`
`5,162,143
`11/1992 Porter et al.
`. 428/179
`..................... 156/73.1
`5,167,740 12/1992 Michaelis et al.
`5,211,291
`5/1993 Kelley et al.
`........................... 209/680
`
`5,221,008
`6/1993 Derrick, Jr. et al.
`. 209/269
`5,256,292 10/1993 Cagle ...................................... 210/499
`5,312,508
`5/1994 Chisholm ................................ 156/292
`
`5,330,057
`7/1994 Schiller et al.
`.
`. 209/392
`............................... 210/488
`5,385,669
`1/1995 Leone, Sr.
`5,392,925
`2/1995 Seyffert
`................................... 209/405
`
`. 156/308.2
`5,417,793
`5/1995 Bakula .....
`5/1995 Derrick et al.
`.......................... 210/388
`5,417,858
`5,417,859
`5/1995 Bakula .................................... 210/388
`
`5,490,598
`2/1996 Adams .....
`209/403 X
`3/1997 Deister et al.
`.......................... 210/388
`5,614,094
`5,636,749
`6/1997 Wojclechowski
`....................... 209/403
`
`5,720,881
`2/1998 Derrick et al.
`..
`. 210/388
`............................... 204/489
`5,851,393
`12/1998 Carr et al.
`5,868,929
`9/1999 Derrick et al.
`.......................... 210/388
`5,876,552
`3/1999 Bakula ................................. 156/308.2
`
`FOREIGN PATENT DOCUMENTS
`
`2161715A of 1984 United Kingdom .
`2161715B of 1984 United Kingdom .
`PCT/GB91/
`00957 of 1991 WIPO .
`PCT/US94/
`00243
`
`of 1994 WIPO .
`
`|PR2018—00015
`Petitioners Ex. 1008 p. 2
`
`IPR2018-00015
`Petitioners Ex. 1008 p. 2
`
`

`

`6,032,806
`
`Page 3
`
`PCT/EP96/
`03103
`
`of 1996 WIPO .
`
`OTHER PUBLICATIONS
`
`“Advanced Wirecloth,
`1993.
`
`Inc.,” Advanced Wirecloth,
`
`Inc.,
`
`“CPI Group, Inc.,” CPI Group, Inc., 1990.
`“LM3 Full—Flo TMShale Shaker,” Sweco Oilfield Services,
`1991.
`
`“The Future of Fine Screening,” Derrick Equipment Co.
`1993.
`
`Pending US. application No. 08/220,101 filed Mar. 30, 1994
`entitled “Screen For Vibrating Separator.”
`Amendment Under 37 CFR 1.115 in pending U.S. applica-
`tion No. 08/220,101.
`Mcnally Coal Preparation Manual M 576, pp. iii,73—96, 216
`(1978).
`
`Layered Shale Shaker Screens Improve Mud Solids Control,
`World Oil, 1978.
`The Brandt Company General Catalog 1982—1983, 4 pages,
`1982.
`
`Take the Drilled Solids Out, The Brandt Company, Sep.
`1980.
`
`Sweco Full—Flow, Sweco, Inc. 1992.
`Catalog 105 H&K Perforated Materials, Harrington & King-
`Perforating Co., 1988.
`Sweco Oilfield Services, Composite Catalog, 1992.
`Screening Equipment Handbook, Pankratz, 1988.
`Supertaut Mud Cleaner Screens, Sweco Oilfield Services,
`1992.
`
`Filtration & Separation, Flo Trend Systems, Inc. 1989.
`Clean Liquids/Dry Solids, Flo Trend Systems, Inc. 1989.
`
`|PR2018-00015
`Petitioners Ex. 1008 p. 3
`
`IPR2018-00015
`Petitioners Ex. 1008 p. 3
`
`

`

`US. Patent
`
`Mar. 7,2000
`
`Sheet 1 0f 28
`
`6,032,806
`
`
`
`FIG. 1B
`
`
`
`
`'5
`
`/ IO
`l2!
`
`|PR2018—00015
`Petitioners Ex. 1008 p. 4
`
`IPR2018-00015
`Petitioners Ex. 1008 p. 4
`
`

`

`
`
`IPR2018-00015
`Petitioners Ex. 1008 p. 5
`
`

`

`US. Patent
`
`Mar. 7,2000
`
`Sheet 3 0f 28
`
`6,032,806
`
`
`
`|PR2018—00015
`Petitioners Ex. 1008 p. 6
`
`IPR2018-00015
`Petitioners Ex. 1008 p. 6
`
`

`

`
`
`IPR2018-00015
`Petitioners Ex. 1008 p. 7
`
`

`

`U. S. Patent
`
`Mar. 7,2000
`
`Sheet50f28
`
`6,032,806
`
`
`
`
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`
`
`II— E
`
`IPR2018-00015
`Petitioners Ex. 1008 p. 8
`
`

`

`6,032,806
`
`KO
`
`FIG
`
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`IPR2018-00015
`Petitioners Ex. 1008 p. 9
`
`

`

`
`
`IPR2018-00015
`Petitioners Ex. 1008 p. 10
`
`

`

`US. Patent
`
`Mar. 7,2000
`
`Sheet 8 0f 28
`
`6,032,806
`
`W I
`
`80
`
`FIG. 7B
`82
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`
`|PR2018—00015
`Petitioners Ex. 1008 p. 11
`
`IPR2018-00015
`Petitioners Ex. 1008 p. 11
`
`

`

`US. Patent
`
`Mar. 7, 2000
`
`Sheet 9 0f 28
`
`6,032,806
`
`93
`
`
`
`5
`
`0
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`
`Petitioners Ex. 1008 p. 12
`
`IPR2018-00015
`Petitioners Ex. 1008 p. 12
`
`

`

`US. Patent
`
`Mar. 7, 2000
`
`Sheet 10 0f 28
`
`6,032,806
`
`FIG. 9
`
`0
`
`02
`
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`
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`
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`
`FIG. [3
`
`I43
`
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`
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`
`|PR2018—00015
`Petitioners Ex. 1008 p. 13
`
`IPR2018-00015
`Petitioners Ex. 1008 p. 13
`
`
`
`
`
`

`

`US. Patent
`
`Mar. 7, 2000
`
`Sheet 11 0f 28
`
`6,032,806
`
`
`
`FIG. [4
`
`IPR2018-00015
`Petitioners Ex. 1008 p. 14
`
`

`

`U S Patent
`
`Mar. 7, 2000
`
`Sheet 12 0f 28
`
`6,032,806
`
`
`
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`
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`
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`
`|PR2018—00015
`Petitioners Ex. 1008 p. 15
`
`IPR2018-00015
`Petitioners Ex. 1008 p. 15
`
`
`
`
`
`
`

`

`US. Patent
`
`Mar. 7, 2000
`
`Sheet 13 0f 28
`
`6,032,806
`
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`|PR2018—00015
`Petitioners Ex. 1008 p. 16
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`IPR2018-00015
`Petitioners Ex. 1008 p. 16
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`

`

`US. Patent
`
`Mar. 7, 2000
`
`Sheet 14 0f 28
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`6,032,806
`
`
`
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`
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`|PR2018—00015
`Petitioners Ex. 1008 p. 17
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`IPR2018-00015
`Petitioners Ex. 1008 p. 17
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`

`

`US. Patent
`
`Mar. 7, 2000
`
`Sheet 15 0f 28
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`6,032,806
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`|PR2018—00015
`Petitioners Ex. 1008 p. 18
`
`IPR2018-00015
`Petitioners Ex. 1008 p. 18
`
`

`

`US. Patent
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`|PR2018—00015
`Petitioners Ex. 1008 p. 19
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`IPR2018-00015
`Petitioners Ex. 1008 p. 19
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`

`US. Patent
`
`Mar. 7, 2000
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`|PR2018—00015
`Petitioners Ex. 1008 p. 20
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`IPR2018-00015
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`

`

`US. Patent
`
`Mar. 7,2000
`
`Sheet 18 0f 28
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`6,032,806
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`
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`FIG.34
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`

`US. Patent
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`Mar. 7, 2000
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`Sheet 19 0f 28
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`

`

`US. Patent
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`Mar. 7, 2000
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`Sheet 20 0f 28
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`6,032,806
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`IPR2018-00015
`Petitioners Ex. 1008 p. 23
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`

`

`US. Patent
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`Mar. 7,2000
`
`Sheet 21 0f 28
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`6,032,806
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`|PR2018—00015
`Petitioners Ex. 1008 p. 24
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`IPR2018-00015
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`

`

`US. Patent
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`Mar. 7, 2000
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`Sheet 22 0f 28
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`6,032,806
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`IPR2018-00015
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`

`

`US. Patent
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`Mar. 7, 2000
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`Sheet 23 0f 28
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`6,032,806
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`|PR2018—00015
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`|
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`IPR2018-00015
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`

`

`US. Patent
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`Mar. 7, 2000
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`Sheet 24 0f 28
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`6,032,806
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`

`

`US. Patent
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`Mar. 7, 2000
`
`Sheet 25 0f 28
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`|PR2018—00015
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`

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`US. Patent
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`Mar. 7, 2000
`
`Sheet 26 0f 28
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`6,032,806
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`US. Patent
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`Mar. 7, 2000
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`Sheet 27 0f 28
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`US. Patent
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`Mar. 7, 2000
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`Sheet 28 0f 28
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`|PR2018—00015
`Petitioners Ex. 1008 p. 31
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`IPR2018-00015
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`

`

`6,032,806
`
`1
`SCREEN APPARATUS FOR VIBRATORY
`SEPARATOR
`
`RELATED APPLICATIONS
`
`This application is a division of US. application Ser. No.
`08/786,515 filed Jan. 21, 1997 which is a continuation in
`part of the following co-owned applications and patents:
`U.S. Ser. No. 29/048,575 filed Jan. 4, 1996, now US. Pat.
`No. D 377,636, which is a continuation of US. Ser. No.
`29/014,571, now US. Pat. No. D 366,040 issued on Jan. 9,
`1996 which is a continuation-in-part of US. applications:
`Ser. No. 07/956,123 filed Apr. 30, 1993, now US. Pat. No.
`5,385,669 issued on Jan. 31, 1995; and Ser. No. 08/105,696
`filed Aug. 12, 1993, now US. Pat. No. 5,392,925 issued on
`Feb. 28, 1995; US. Ser. No. 08/504,495 filed Jul. 20, 1995
`entitled “Shale Shaker Screen” issued as US. Pat. No.
`5,598,930 on Feb. 4, 1997; US. Ser. No. 08/598,566 filed
`Feb. 12, 1996 now abandoned entitled “Screen For Vibrating
`Separator” which is a continuation-in-part of US. Ser. No.
`08/220/101 filed Mar. 30, 1994 now US. Pat. No. 5,490,598
`issued Feb. 13, 1996. All of these related applications and
`patents are incorporated herein in their entirety for all
`purposes.
`
`BACKGROUND OF THE INVENTION
`
`1. Field of the Invention
`
`The present invention is directed to vibratory screens, to
`filtering screens, to such screens that are generally flat or that
`are not flat,
`to devices with such screens, and to shale
`shakers with such screens, and to shakers for separating
`particles.
`2. Description of Related Art
`in drilling mud used in
`The need for solids control
`hydrocarbon well drilling is well known in the prior art.
`Drilling mud, typically a mixture of clay and water and
`various additives, is pumped down through a hollow drill
`string (pipe, drill collar, bit, etc.) into a well being drilled and
`eXits through holes in a drillbit. The mud picks up cuttings
`(rock) and other solids from the well and carries them
`upwardly away from the bit and out of the well in a space
`between the well walls and the drill string. At the top of the
`well, the solids-laden mud is discharged over a shale shaker,
`a device which typically has a series of screens arranged in
`tiered or flat disposition with respect to each other. The prior
`art discloses a wide variety of vibrating screens, devices
`which use them, shale shakers, and screens for shale shakers.
`The screens catch and remove solids from the mud as the
`
`mud passes through them. If drilled solids are not removed
`from the mud used during the drilling operation, recircula-
`tion of the drilled solids can create weight, viscosity, and gel
`problems in the mud, as well as increasing wear on mud
`pumps and other mechanical equipment used for drilling.
`In some shale shakers a fine screen cloth is used with the
`
`vibrating screen. The screen may have two or more overly-
`ing layers of screen cloth. The prior art discloses that the
`layers may be bonded together; and that a support, supports,
`or a perforated or apertured plate may be used beneath the
`screen or screens. The frame of the vibrating screen is
`resiliently suspended or mounted upon a support and is
`caused to vibrate by a vibrating mechanism, e.g. an unbal-
`anced weight on a rotating shaft connected to the frame.
`Each screen may be vibrated by vibratory equipment to
`create a flow of trapped solids on top surfaces of the screen
`for removal and disposal of solids. The fineness or coarse-
`ness of the mesh of a screen may vary depending upon mud
`flow rate and the size of the solids to be removed.
`
`5
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`Many screens used with shale shakers are flat or nearly
`flat (i.e. substantially two-dimensional). Other screens, due
`to corrugated, depressed, or raised surfaces are three-
`dimensional. US. Pat. Nos. 5,417,793; 5,417,858; and
`5,417,859 disclose non-fiat screens for use with shale shak-
`ers. These screens have a lower planar apertured plate with
`a multiplicity of spaced-apart apertures or openings there-
`through. Undersides of troughs of undulating screening
`material are bonded to the apertured plate. Such screens
`present
`a variety of problems, deficiencies, and
`disadvantages, including: decreased flow area due to area
`occluded by solid parts of the apertured plate; necessity to
`either purchase relatively expensive apertured plate or pro-
`vide for in-house perforating of a solid plate; plate weight
`increases wear on parts such as rubber screen supports or
`cushions and can inhibit required vibration;
`large plate
`surface area requires relatively large amount of bonding
`means for bonding screens to the plate; and a finished screen
`which is relatively heavy increases handling problems,
`hazards, and cost of shipping.
`Vibrating screens have been employed for many years to
`separate particles in a wide array of industrial applications.
`One common application of vibrating screens is in drilling
`operations to separate particles suspended in drilling fluids.
`The screens are generally flat and are mounted generally
`horizontally on a vibrating mechanism or shaker that imparts
`either a rapidly reciprocating linear, elliptical or circular
`motion to the screen. Material from which particles are to be
`separated is poured onto a back end of the vibrating screen,
`usually from a pan mounted above the screen. The material
`generally flows toward the front end of the screen. Large
`particles are unable to move through the screen remaining
`on top of the screen and moving toward the front of the
`screen where they are collected. The smaller particles and
`fluid flows through the screen and collects in a pan beneath
`the screen.
`
`A vibrating screen may be formed from one or more
`layers of wire mesh. Wire mesh is generally described with
`reference to the diameter of the wires from which it is
`
`woven, the number wires per unit length (called a mesh
`count) and the shape or size of the openings between wires.
`Wire mesh comes in various grades. “Market” grade mesh
`generally has wires of relative large diameter. “Mill” grade
`has comparatively smaller diameter wires and “bolting
`cloth” has the smallest diameter wire. The type of mesh
`chosen depends on the application. Smaller diameter wires
`have less surface and thus less drag, resulting in greater flow
`rates. Smaller diameter wires also result, for a given opening
`size, in a larger percentage of open area over the total area
`of the screen, thus allowing greater flow rates and increased
`capacity. However, screens of bolting cloth tears more easily
`than market or mill grade screens, especially when used in
`harsh conditions such as drilling and mining operations. The
`smaller diameter wires tend to have less tensile strength and
`break more easily, and the finer mesh also tends not to retain
`its shape well.
`Most meshes suffer from what is termed as “near sized
`
`particle blinding. During vibration, wires separate enough to
`allow particles of substantially the same size or slightly
`larger than the openings to fall between the wires and
`become ledged, thus “blinding” the openings of the screen
`and reducing capacity of the screen. If a particle becomes
`lodged when the wires are at a maXimum distance apart, it
`is almost impossible to dislodge the particle. Sometimes,
`however, wires will subsequently separate further to release
`the lodged particle. Unfortunately, some wire mesh, espe-
`cially bolting cloth, is tensioned. Tensioning restricts move-
`
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`6,032,806
`
`3
`ment of the wires. Restricting movement assists in holding
`the shape of the wire mesh, keeping the size of the openings
`consistent to create a more consistent or finer “cutting point”
`and reducing abrasion from wires rubbing against each
`other. However, restricted movement of the wires reduces
`the probability that, once a near sized particle becomes
`stuck,
`the wires will subsequently separate to allow the
`particle to pass. Use of smaller diameter wires, with smaller
`profiles, helps to reduce blinding. With a smaller diameter
`wire, a particle is less likely to become lodged midway
`through the opening.
`Multiple layers of mesh may be used to alleviate blinding.
`US. Pat. No. 4,033,865, describes layering two meshes in a
`manner that results in at least one wire of the lower of the
`
`two meshes bisecting each opening in the upper mesh. The
`openings in each mesh are at least twice as wide as the
`diameters of the wires and the lower mesh has openings the
`same size as or slightly larger than the openings in the upper
`mesh. The lower mesh, when held tightly against the upper
`mesh, prevents particles from migrating far enough into an
`opening in the upper mesh to be trapped. Some relative
`movement of the layers also helps to dislodge particles
`caught in the upper layer. The two-layer arrangement has the
`further benefit of a finer “cutting point,” allowing smaller
`particles to be separated out. A third “backing” layer of
`relatively coarse, mill grade mesh is often used to carry most
`of the load on the screen and to increase the tensile strength
`of the screen.
`
`Another problem faced in most applications is the tearing
`of the screen. The problem can be especially acute in heavy
`duty applications such as drilling and mining. A torn screen
`must be replaced or repaired. To facilitate repair, the screen
`layers are bonded to a rigid or semi-rigid support panel that
`has a pattern of large openings, forming on the screen a
`plurality of small cells of wire mesh. When a tear occurs in
`the screen, the mesh remaining within the cell in which the
`tear occurred is cut out and the cell is plugged. The capacity
`of the screen is diminished but its life is extended. Typically,
`several cells of a screen can be repaired before its capacity
`drops far enough to require replacement. Unfortunately,
`bonding the screen to the support panel further restricts
`relative movement of the layers and the wires in each mesh
`layer, thus compounding the problem of blinding.
`Blinding and tearing of the screens reduce the capacity of
`the screen continually through its useful
`life. Although
`capacity can be increased by increasing the total area the
`screens, the size of the screen is limited in most applications,
`such as on drilling rigs, especially those on offshore plat-
`forms. There has thus been generally a trade-off between
`capacity, longevity, repairability and resistance to blinding
`of the screens.
`
`There is a need for a supported (either non-flat or flat)
`screen which is consumable, efficient and cost-effective, yet
`readily and inexpensively made, easy to handle, and rela-
`tively inexpensive to transport.
`
`SUMMARY OF THE PRESENT INVENTION
`
`The present invention discloses, in certain embodiments,
`a screen for vibrating screen apparatus. The screen has one
`or more upper layers of screen, screen cloth, and/or mesh. If
`more than one layer is used, they may be bonded together at
`discrete points, at discrete areas, or over their entire surface.
`The layer or layers are mounted on frame apparatus which
`may include a solid side support on each of two spaced apart
`sides of the layer(s), or may include a full four sided screen
`frame. A strip or strips of support material (e.g. flat steel,
`
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`aluminum or plastic strips—of any width, but in certain
`preferred embodiments ranging between a half inch to three
`inches in width; and of any thickness, but in certain pre-
`ferred embodiments ranging between one-thirty second and
`one-eighth inches thick, or rods of these materials with a
`diameter between one-thirty second and one-eighth inches;
`any screen may use strips made from different materials, e.g.
`cross-strips of plastic and end strips of steel, or vice versa)
`are secured across two or more frame sides. With respect to
`a two sided frame wherein the two sides are parallel and
`spaced apart, a strip or strips may be, according to this
`invention, disposed parallel to the two sides; and, if more
`than one strip is used, spaced apart across the area of the
`layer or layers. It is also within the scope of this invention
`to use a strip or strips which are disposed in a manner
`non-parallel to the two sides. In one aspect such non-parallel
`strips may extend diagonally from one end of one side of the
`frame, across the layer or layers, to a diagonally opposite
`end of the other side. In another aspect such a strip may
`extend from any point of a frame side to any point on a
`non-framed side of the layer or layers. Any such strip (or
`rod) may be bonded, sintered, welded or otherwise secured
`(her