RELATED APPLICATIONS

The present application claims priority to US Provisional Application No. 62/829,989 filed April 5, 2019, which is hereby incorporated by reference.

TECHNICAL FIELD

The present disclosure relates to screen filters for liquid filtration. More particularly, the present disclosure is related to screen filters that include honeycomb or matrix-style support elements imparting structural strength and desired fluid handling or light diffusion characteristics to the screen filter as well as the related methods of fabrication.

BACKGROUND

Filter screens formed of shaped wire, such as for example, wedge wire or Vee-Wire®, are commonly used in a variety of liquid filtering applications. For example, filter screens can take the form of flat filter screens for use in pressure and gravity filtration vessels or in media filtration applications. In other representative examples, cylindrical filter screens are frequently used in intake screens or water wells. In all of these applications, strength and durability can be an issue as the filter screens may be supporting layers of filter media or can be subject to damage by impacts from submerged debris.

In order to address these concerns, filter screens can be fabricated using heavier or more robust materials of construction. The traditional filter screen can include wire spirally wrapped and welded to a set of longitudinal support members where the tensile or weight bearing strength of the screen is then dependent, at least in part, on the strength of the longitudinal support members. As such, one way to increase the strength of the filter screen is to utilize larger or heavier gage longitudinal support members. While these larger support members can be used to provide higher screen strength, these larger support members can also result in reduced fluid flow rates and increased production costs. As such, a manufacturer can be forced to choose between the benefits of higher strength but at the cost of efficiency and economy. SUMMARY

The embodiments of filers screens disclosed herein can generally comprise a filter screen that includes a matrix support element, such as, for example, a honeycomb-type support structure. In various embodiments, the filter screen can be fabricated from shaped wires, such as, for example, wedge wire or Vee-Wire, or alternatively, the filter screen can comprise a prefabricated or machined screen that includes perforations of a desired shape and size. In embodiments, these honeycomb-type support structures can be utilized to support a variety of shaped screen configurations such as, for example, flat, arcuate, cylindrical, spherical, or any other conventional or suitable screen shape. In certain embodiments, the filter screen can be fabricated to have a desired liquid filtering performance while in certain other embodiments, the filter screen can be fabricated to have a desired aesthetic performance, such as, for example, the diffusion of sunlight in architectural applications.

In an embodiment, a shaped wire screen structure can include a first screen which is fabricated by welding a wire to a plurality of longitudinal support members. In a preferred embodiment, the wire comprises a continuous length of wire that is wound about and welded to the longitudinal support members. The continuous length of wire can comprise shaped wires, such as wedge wire or Vee-Wire that has a substantially triangular cross-section. The wedge wire screen structure can also include a matrix support element formed of a continuous honeycomb matrix. The support screen can further define a first support side and a second support side. The first screen can be operably coupled, for example, by welding, use of adhesives, clamps or fasteners such that the first screen is operably coupled to the first support side. In some embodiments, the second support side can be similarly coupled to a second screen that substantially resembles the construction of the first screen. Alternatively, a perforated sheet can be operably coupled to a second side of the matrix support element to substantially enclose the matrix support element.

In another representative embodiment of the invention, a matrix support element generally defines a plurality of matrix apertures between a first support side and a second support side. Each matrix aperture can have an aperture cross-section selected from the group comprising: a circular cross-section, an elliptical cross-section, a partially circular cross- section, an asymmetrical circular cross-section and a polygonal cross-section. In one embodiment, each matrix aperture in the matrix support element can share the same aperture cross-section or alternatively, the matrix support element and include two or more different aperture cross-sections defined by the plurality of matrix apertures. The matrix support element can have a support thickness as measured between the first support side and the second support side. In some embodiments, the matrix support element can be configured to provide beneficial flow properties through the plurality of matrix apertures in addition to simply providing added support strength. For example, a support thickness defined between the first support side and the second support side as well as an aperture diameter or aperture cross-sectional area can be configured to provide desirable flow characteristics, such as flow velocities or pressure drops or to act as flow straighteners to reduce turbulence and direct water flow out the matrix support element. In certain embodiments, an aperture flow path extending between the first and second support sides of each individual matrix aperture can be arranged so as to be generally perpendicular to a screen plane defined by a filter screen while in other embodiments, the aperture flow path can have an angled or non-perpendicular arrangement with respect to the screen plane.

In yet another representative embodiment, a shaped wire screen structure can include a first screen which is fabricated by welding a continuous length of wire directly to a first support surface of a matrix support element. In this configuration, the longitudinal support members are eliminated.

In another representative embodiment, the first screen comprises a first frame surrounding a first screen perimeter of the first screen. In this embodiment, the first frame includes one or more first frame attachment assemblies. Similarly, the support screen can comprise a support frame surrounding a support screen perimeter of the support screen. The support frame includes one or more support frame attachment assemblies. In these embodiments, at least one of the first frame and the support frame includes a frame attachment assembly.

The above summary is not intended to describe each illustrated embodiment or every implementation of the subject matter hereof. The figures and the detailed description that follow more particularly exemplify various embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

Subject matter hereof may be more completely understood in consideration of the following detailed description of various embodiments in connection with the accompanying figures, in which:

FIG. 1 is an isometric view of a cylindrical embodiment of an individual screen for a water intake screen, according to embodiments.

FIG. 2 is a cutaway view of a screen having a matrix support element, according to embodiments. FIG. 3A is an exploded isometric view of a screen having a matrix support element and a shaped wire screen surface, according to embodiments.

FIG. 3B is an exploded isometric view of screen having a matrix support element and a shaped wire screen surface with support rods, according to embodiments.

FIG. 3C is a side view of an end of a screen section screen having a matrix support element and a shaped wire screen surface on one side of the matrix support element and a perforated sheet on a second side, according to embodiments.

FIG. 4A is a side view of an end of a screen section having a matrix support element with screen surfaces on both sides of the matrix support element, according to embodiments.

FIG. 4B is a side view of an end of a screen section having a matrix support element with screen surfaces and support rods on both sides of the matrix support element, according to embodiments.

FIG. 5 is an isometric view of a cylindrical embodiment of an individual screen for a water intake screen, according to embodiments.

FIG. 6A is a top, perspective view of a representative embodiment of a flat filter screen of the present invention.

FIG. 6B is a bottom, perspective view of the flat filter screen of FIG. 6 A.

FIG. 7A is a top, perspective view of a representative embodiment of a flat filter screen of the present invention.

FIG. 7B is a bottom, perspective view of the flat filter screen of FIG. 7 A.

FIG. 8A is a top, perspective view of a representative embodiment of a flat filter screen of the present invention.

FIG. 8B is a bottom, perspective view of the flat filter screen of FIG. 8 A.

FIG. 9A is a top, perspective view of a representative embodiment of a flat filter screen of the present invention.

FIG. 9B is a top, perspective view of a representative embodiment of a flat filter screen of the present invention.

FIG. 10A is a top, perspective view of a representative embodiment of a flat filter screen of the present invention.

FIG. 10B is a bottom, perspective view of the flat filter screen of FIG. 10 A.

FIG. IOC is a top, perspective view of a representative embodiment of a flat filter screen of the present invention.

FIG. 10D is a top, perspective view of a representative embodiment of a flat filter screen of the present invention. FIG. 11A is a top, perspective view of a representative embodiment of a flat filter screen of the present invention.

FIG. 1 IB is a side view of the flat filter screen of FIG. 11 A.

FIG. 11C is a bottom, perspective view of the flat filter screen of FIG. 11 A.

FIG. 12A is a top, perspective view of a representative embodiment of a flat filter screen of the present invention.

FIG. 12B is a bottom, perspective view of the flat filter screen of FIG. 12 A.

FIG. 13 is a bottom, perspective view of a representative embodiment of a flat filter screen of the present invention.

FIG. 14A is a top, perspective view of a representative embodiment of an arcuate filter screen of the present invention.

FIG. 14B is a bottom, perspective view of the arcuate filter screen of FIG. 14A.

FIG. 15 is a top, perspective view of a representative embodiment of a flat filter screen of the present invention.

FIG. 16A is a bottom, perspective view of a representative embodiment of a flat filter screen of the present invention.

FIG. 16B it a top, partially exploded, perspective view of the flat filter screen of FIG.

16 A.

FIG. 17 is a bottom, perspective view of a representative embodiment of a flat filter screen of the present invention.

While various embodiments are amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the claimed inventions to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the subject matter as defined by the claims.

DETAILED DESCRIPTION OF THE DRAWINGS

The following detailed description of embodiments refers to the accompanying drawings, which illustrate specific embodiments. Other embodiments having different structures and operation do not depart from the scope of the present disclosure.

The disclosed embodiments can include shaped wires, such as, for example, a wedge wire or“Vee-Wire”® screen that is supported by various matrix support elements or honeycomb-type support structures. Alternatively, the embodiments can comprise a filter plate that has been fabricated and/or machined to have perforations with desired shaped and sizes. In embodiments, honeycomb-type support structures can support various shaped screens, such as flat, cylindrical, spherical, or any other suitable screen shape.

Referring to the drawings, where like reference numerals refer to the same or similar parts, FIG. 1 shows a representative submerged intake assembly 100 for submersion in a river, lake or other body of water. While a submerged intake assembly 100 is one application in which matrix support elements can be utilized, it will be understood that matrix support element of the present invention can be utilized in a variety of liquid filtration applications including, for example, conventional gravity and pressure filter applications, centrifugal filter applications, media filtration applications. Furthermore, the matrix support element of the present invention can be utilized to provide desired aesthetic appearances, for example, diffusion of sunlight or other artificial light, in architectural applications.

As seen in FIG. 1, submerged intake assembly 100 includes a plurality of filter screens 102 that are mounted to filter liquid as it passes into a central manifold of the submerged intake assembly 100. As seen in FIGS. 1, 2, 5, 14A and 14B, representative filter screens can be spherical, semi-cylindrical or otherwise arcuate arrangements. In other representative embodiments as seen in FIGS. 6A-13 and 15-17, a filter screen 102 can be a flat or substantially planar arrangement. Multiple filter screens 102 can be installed in a side-by-side or end-to-end arrangement to accommodate desired filtering capacities or to cover desired surfaces in an architectural application. When viewed from a distance, an exterior surface 104 of the filter screens 102 can appear smooth and/or continuous, while in actuality, the exterior surface 104 will contain openings such as, for example, slots when the filter screen 102 is formed with wedge or Vee-wire or perforations when the filter screen is formed of a prefabricated or machined panel.

In one representative embodiment shown in FIG. 2, the submerged screen intake 100 can include filter screen 102 formed of a plurality of spaced apart filter wires 110 supported and welded to a plurality of support rods 111. A matrix support element 112 is then welded to the support rods 111 to complete the assembly of the filer screen 102. In some embodiments, the filter wires 110 can comprise wedge or Vee-wire such that the completed filter screen 102 performs filtering and screening as commonly associated with Vee-wire screens but with the additional support and reinforcement of the matrix support element 112. In certain applications, it can be advantageous to have the spacing and sizes of wires 110 vary along the lengths of the filter screens 102. The filter screens 102 can be fabricated based on the same principles as disclosed in U.S. Patent Nos. 6,663,774 and 7,425,264, both of which are hereby incorporated by reference in their entirety. In embodiments such as those shown in FIGS. 10A-10D, the filter screens 102 can replace the filter wires 110 and support rods 111 with a prefabricated or machined filter plate 140. In other alternative embodiments such as those shown in FIGS. 10A and 10B, filter screen 102 can include combinations of filter wires 110 and support rods 111 and prefabricated filter plates 140. Screen intake assembly 100 can further include end fittings, herein depicted as weld rings 114, at each end for connection of additional filter screens 102 or end plates 116 based on desired size and capacity.

As seen in FIGS. 2, 3 A and 3B, the matrix support element 112 can be comprised of a connected array of“tubes” 116 being defined by apertures 118 and rigid tube walls 120 as to define a first end 122 and a second end 124 and a tube interior 126 with a tube flowpath 128. In this embodiment, tubes 116 are formed such that the apertures 118 have a hexagonal shape so as to resemble a traditional honeycomb matrix. Typically, the matrix support element 112 will be formed of appropriate metallic materials to provide high strength and to encourage a welding connection to filter screens 102. In certain applications, it can be advantageous to have matrix support element 112 be formed of polymeric materials and/or to allow the matrix support element 112 to attach to the filter screen 102 via other attachment or bonding methods including, for example, adhesives or other mechanical fastening methods.

In the "Vee-Wire" type of screen, as depicted in FIG. 3A, a filtering surface 130 is formed by wires 110 with a V-shaped cross-section, meaning that they each have a generally triangular-shaped cross-section and which are parallel at constant intervals, the space between wires framing the slots of the screen. When using wires of V-shaped cross-section, a channel is created between opposing side surfaces of consecutive wires. Because of the triangular shaped cross-section of the wires in one embodiment, the channels between consecutive wires open away from the plane defined by the face surfaces of the filter wires. Put another way, the filter channels do not have parallel walls, but instead flare from the face surfaces to the points of the wires.

As shown in FIG. 3 A, wires 110 can be resistance welded one or both of the first end 122 and second end 124, i.e., a top or bottom side of matrix support element 112. The rigid tube walls 120 can have relatively thick or thinner walls in order to maximize desired performance such as, for example, in order to maximize the effective opening of apertures 118 or to increase structural strength or crush resistance of the matrix support element 112. As such, filter screens 102 that include matrix support element 112 can have the dual advantage of being both very strong, due to the structural integrity of matrix support element 112 and as well as being resistant to clogging. In one method of manufacture as described with respect to screen intake assembly 100, filter screen 102 can be constructed by positioning or mounting a matrix support element 112 around a cylindrical forming wheel (not shown) and secured in place via clamp or other suitable structure. The wheel, and thus the cylinder of matrix support element 112, is then rotated and shaped wire 110 is continuously and spirally wrapped around the rotating cylinder of matrix support element 112. At each point where the shaped wire 110 intersects a portion of matrix support element 112, an electrical charge is conducted through the intersection and the wheel, thereby welding the shaped wire 110 to the portion of matrix support element 112 via resistance welding. The result is a cylindrical filter screen 102 formed with a cylindrical matrix support element 112 surrounded by spirally-wrapped shaped wire 110. In an alternative fabrication method as depicted in FIG. 3B, support rods 111 can form an intermediate support structure between the cylindrical matrix support element 112 and the spirally-wrapped shaped wire 110. Alternatively, as depicted in FIG. 3C, a prefabricated or machined filter plate 140 can be coupled to second end 124 of matrix support element 112 while spirally-wrapped shaped wire 110 and/or support rods 111 are connected to first end 122. In such an embodiment, prefabricated or machined filter plate 140 can act as a secondary filtering screen and/or provide additional structural support.

Resistance welding is one example of welding technique that can be used in fabricating embodiments herein. However, it should be understood that different welding techniques could be used as determined by one of ordinary skill in the art. Weld rings 114 can be welded to the matrix support element 112 with a fillet weld on the surface of the weld rings 114 that is on the interior of the intake screen assembly 100.

In alternative embodiments as depicted in FIGS. 4A and 4B, shaped wire 110 can be attached directly to both the first end 122 and second end 124 of the matrix support element 112 or support rods 111 can function as an intermediate attachment member between the shaped wire 110 and both the first end 122 and second end 124 of the matrix support element 112.

FIG. 5 illustrates another embodiment of a screen intake assembly 100 that is made up of filter screens 102 of different sizes that can be combined to define a complete assembly. As illustrated, two filter screens 102 and two half screens 102a can be fabricated similarly with matrix support element 112 and then combined to define the screen intake assembly 100.

As illustrated and described, FIGS. 6A-17 illustrate a variety of configurations of representative filter screens 102 of the present invention. Though they make reference to either flat or arcuate versions, it will be understood that each of the embodiments can be fabricated in either a flat or arcuate arrangement depending upon desired performance, for example, pressure drops, flow velocities, mounting location and such for filtering applications or to provide desired light diffusion in architectural and aesthetic installations.

As seen in FIGS. 6 A and 6B, a filter screen 220 can comprise a filtering surface 130 formed with wires 110 attached to support rods 111. The filtering surface 130 is coupled to the matrix support element 112 at the first end 122. As shown, the rigid tube wall 120 can define apertures 118 having a hexagonal cross-section. FIGS 7A and 7B illustrate a similar filter screen 230 but having the filtering surface 130 defined by directly attaching wires 110 to the first end 122 and eliminating the support rods 111.

FIGS. 8A and 8B illustrate another variation of a filter screen 240 including a pair of filtering surfaces 242a, 242b attached to opposed sides of the matrix support element 112. As illustrated, each of the filtering surfaces 242a, 242b is formed with wires 110 attached to support rods 111. Filtering surface 242a is attached to the first end 122 of the matrix support element 112 while filtering surface 242b is attached to the send end 124. As illustrated, filtering surfaces 242a, 242b include support rods 111 that are arranged in a perpendicular orientation such that the wires 110 are similarly mounted in a perpendicular orientation. Having the support rods 111 and wires 110 in such an arrangement can provide a desired performance though it will be understood that filtering surfaces 242a, 242b can also be arranged as a mirror image of each other. FIGS. 9 A and 9B illustrate another variation of a filter screen 250 where a pair of filtering surfaces 252a, 252b are attached on opposed sides of the matrix support element 112. Filtering surfaces 252a, 252b are formed by directly attaching wires 110 to the first end 122 and second end 124 absent the support rods 111. Again, it will be understood that filtering surfaces 252a, 252b can include wires 110 residing in parallel or perpendicular relation depending upon desired performance.

As shown in FIGS. 10A and 10B, another variation of a filter screen 260 can comprise at least one filtering surface 262 formed of a pre-fabricated plate 264 that is directly attached to the second end 124 of the matrix support element 112. As illustrated, pre-fabricated plate 264 can comprise a plurality of drilled apertures 266 that are arranged to align with the individual hexagonal apertures 118 of the matrix support element 112. As shown, filter screen 260 can further comprise a second filtering surface 268, herein shown as comprising wires 110 and support rods 111 that is attached to the first end 122 of the matrix support element 112. Filter screen 260 allows a liquid flow through the second filtering surface 268, through the hexagonal apertures 118 and out the apertures 266 on the pre-fabricated plate 264. With reference to FIGS. IOC and 10D, it can be seen that pre-fabricated plate 264 can include a slotted sheet 270 or expanded metal 272. Though not illustrated, it will be understood that pre-fabricated plate 264 could comprise a variety of other configurations including, for example, being perforated and other similar treatments.

As illustrated in FIGS. 11 A, 11B and 11C, a filter screen 280 can comprise a matrix support element 282, shown as a honeycomb matrix, wherein the apertures 118 have rigid tube walls 120 that are angled relative to a screen plane 284 defined by a filtering surface 286. Filtering surface 286 is shown as having wires 110 mounted to support rods 111 that are direct attached to the first end 122 of the matrix support element 282. The angular arrangement of the rigid tube wall 120 relative to the screen plane 284 can be selected to provide desired liquid flow characteristics or even to have a desired light diffusion characteristic in an architectural or aesthetic installation.

As shown in FIGS. 12A and 12B, a filter screen 290 can comprise a matrix support element 292 wherein the apertures 118 have rigid tube walls 120 defining a square or rectangular cross-section 294. It will be understood that rigid walls 120 can be arranged in almost a limitless variety of shapes and geometries to provide desired structural support, desired flow characteristics or to provide desired light diffusion. As shown, a filtering surface 296 formed of wires 110 and support rods 111 can be attached to the first end 122 of the matrix support element 292.

As illustrated in FIG. 13, a filter screen 300 can comprise a matrix support element 302 in which the apertures 118 are filled with a desired filter or process media 304. Representative examples of filter or process media 304 can comprise, for example, catalysts, ion exchange media, activated carbon, granular media, ultrafiltration tubes and other suitable materials. As illustrated, a filtering surface 306 is attached to the first end 122 of the matrix support element 302, with said filtering surface having wires 110 mounted to support rods 111. In use, a liquid can flow through the filtering surface 306 whereby particulates of a desired size are prevented from entering the first end 122 of the apertures 118. The liquid then flows through or past the process media 304 whereby the liquid has a desired interaction with the process media 304 as it flows to the second end 124 of the apertures 118. Though not illustrated, it will be understood that a second filtering surface can be attached to the second end 124 of matrix support element 302 to retain the process media within the apertures 118.

As shown in FIGS. 14A and 14B, an arcuate filter screen 310 is shown as having an arcuate filtering surface 312 mounted to an arcuate matrix support element 314. Arcuate filtering surface 312 is illustrated as comprising wires 110 directly attached to the first end surface 312 can further include support rods 111 or could also comprise a pre-fabricated arcuate plate.

Referring now to FIG. 15 A, a filter screen 320 can comprise a filtering surface 322 attached to a matrix support element 324. As illustrated, matrix support element 324 can comprise tube apertures or orifice 326 in one or more rigid tube walls 120 of each aperture 118 to allow flow between adjacent apertures 118. In addition, a perforated collector member or tube 328 can be counted through adjacent apertures 118. With a solid plate 330 mounted to the second end 124 of the matrix support element 324, a liquid flow direction can be changed and total flow divided into a plurality of distinct flow streams as a liquid passes through the filtering surface 322 and enters the apertures 118, where the water is then forced to enter the perforated collector member 328 and transported out of the matrix support element 324.

As shown in FIGS. 16A and 16B, filter screen 340 can be constructed to have desired mixing or to provide a desired process effect such as, for example, a mixed phase (air/water) interface control. Filter screen 340 can comprise a filtering surface 342 that is mounted to a first mounting plate 344. First mounting plate 344 can comprise a prefabricated plate have plate apertures 345. A matrix support element 346 can be mounted to the first mounting plate 344 and can include internal flow tubes 347 that fluidly connect to the plate apertures 345. Matrix support element 346 can attach to a second mounting plate 348 at the second end 124 of the matrix support element 346. On an opposed side of the second mounting plate 348, a lower tube assembly 350 formed of individual tubes 352 is attached. Each individual tube 352 can include one or more tube apertures 354.

As illustrated in FIG. 17, a filter screen 360 can comprise a filter surface 362 and a matrix support element 112. As seen in FIG. 17, filter surface 362 can comprise a plurality of shaped wires 110, herein shown as wedge or Vee wires that have been arranged such that that a flat portion 364 is welded directly to the first end 122 of the matrix support element 112. The arrangement shown in FIG. 17 is a reverse of typical wedge wire screen filters in that the narrowest slot portion is right at the connection of the matrix support element 112 as opposed to be spaced away from the matrix support element 112.

Embodiments disclosed herein may provide relatively more open area for intake of fluid than conventional screens, with added overall strength for applications in dewatering and water supply, and may be of particular benefit for water wells in the mining industry.

Various embodiments of systems, devices, and methods have been described herein. These embodiments are given only by way of example and are not intended to limit the scope of the claimed inventions. It should be appreciated, moreover, that the various features of the embodiments that have been described may be combined in various ways to produce numerous additional embodiments. Moreover, while various materials, dimensions, shapes, configurations and locations, etc. have been described for use with disclosed embodiments, others besides those disclosed may be utilized without exceeding the scope of the claimed inventions.

Persons of ordinary skill in the relevant arts will recognize that the subject matter hereof may comprise fewer features than illustrated in any individual embodiment described above. The embodiments described herein are not meant to be an exhaustive presentation of the ways in which the various features of the subject matter hereof may be combined. Accordingly, the embodiments are not mutually exclusive combinations of features; rather, the various embodiments can comprise a combination of different individual features selected from different individual embodiments, as understood by persons of ordinary skill in the art. Moreover, elements described with respect to one embodiment can be implemented in other embodiments even when not described in such embodiments unless otherwise noted.