Composite screen frame with semi-flexible mechanical strain relief
An apparatus and a method filters particles using a screen assembly with an inner section, an outer section and a screen material. The inner section and the outer section form an opening. The screen material is stretched across the opening and is supported by the inner section. The inner section is flexible relative to the outer section. When particles are introduced to the screen material, the inner section flexes to reduce strain on the screen material.
1. An apparatus comprising:
a screen frame having an inner section and an outer section, the inner section and the outer section defining an opening, the outer section having an innermost edge defining at least a portion of the opening, wherein the inner section comprises a first end and a second end with a length extending between the first end and the second end, wherein the second end of the inner section extends inwardly beyond the innermost edge of the outer section, the inner section and the outer section being integrally formed from a polymeric material wherein a portion of the inner section flexes downwardly with respect to the outer section; and
a screen material stretched across the opening and secured to the outer section of the screen frame wherein the inner section supports the screen material at least partially around the opening.
2. The apparatus of claim 1 further comprising:
a reinforcement member encapsulated within the outer section.
3. The apparatus of claim 1 wherein the inner section of the screen frame has a first hardness and the outer section of the screen frame has a second hardness wherein the first hardness is equal to the second hardness.
4. The apparatus of claim 1 wherein the inner section has a convex upper surface extending upwardly and a lower surface with a concave portion and a planar portion wherein the concave portion permits the inner section to flex wherein the screen material is supported by the upper portion of the inner section.
5. The apparatus of claim 1 wherein the inner section further comprises a notch between the first end and the second end wherein the notch permits the second end of the inner section to flex relative to the first end of the inner section upon application of force to the second end.
6. The apparatus of claim 1 wherein the screen frame is circular.
7. The apparatus of claim 1 wherein the screen frame is rectangular.
8. The apparatus of claim 1 further comprising:
an internal support frame within the opening of the screen frame wherein the internal support frame defines a plurality of cells wherein the internal support frame supports the screen material.
9. The apparatus of claim 1 wherein the internal support frame has a plurality of inner sections extending into the plurality of cells.
10. A method comprising:
forming an outer section and an inner section of a screen frame from a single material, the inner section and the outer section having the same hardness, with the outer section and the inner section extending around an opening, the inner section connected to the outer section, the inner section defining the opening in the screen frame wherein the screen frame has a top surface; and
applying a screen material on the top surface of the screen frame such that the screen material extends across the opening and is supported by the inner section wherein a portion of the inner section flexes downwardly relative to the outer section in response to a force on the screen material.
11. The method of claim 10 further comprising:
preparing a mold to form the outer section and the inner section as a unitary structure.
12. The method of claim 10 further comprising:
melting a portion of the top surface of the screen frame to adhere the screen material to the top surface of the screen frame.
13. The method of claim 10 further comprising:
welding the screen material to the top surface of the screen frame.
14. The method of claim 10 further comprising:
forming the outer section and the inner section of the screen frame around a reinforcement member.
15. The method of claim 10 further comprising:
adding reinforcement particles to the material prior to forming the outer section and the inner section.
16. The method of claim 10 further comprising:
tightening the screen material prior to securing the screen material to the outer section.
17. An apparatus comprising:
a screen frame having an opening, an outer section and an inner section extending around at least a portion of the opening, the inner section being integrally formed with the outer section, the screen frame having a top surface formed by the outer section and the inner section, wherein the inner section extends upwardly from the top surface and beyond an innermost edge of the outer section, the outer section having a first rebound hardness, the inner section having a second rebound hardness where the first rebound hardness equals the second rebound hardness; and
a screen material extending across the opening and the inner section, the screen material secured to the outer section and supported by the inner section adjacent the opening.
18. The apparatus of claim 17 wherein the outer section has an inner edge surrounding the opening and further wherein the inner section extends inwardly beyond the inner edge of the outer section.
19. The apparatus of claim 17 wherein the inner section and the outer section of the screen frame are formed from a single material.
20. The apparatus of claim 19 wherein reinforcement particles are incorporated into the material.