[0001] 1. Field of the Invention
[0002] This invention is directed to vibratory separators and, in certain particular aspects, to shale shakers and to shale shakers with structural members made of composite material.
[0003] 2. Description of Related Art
[0004] Many typical vibratory separators and shale shakers have a container, carrier, housing, or basket to which is secured one or more screens used for separating components of material fed to the vibratory separator or shale shaker. Vibrating apparatus connected to the container, etc. vibrates the container, etc. and the vibrations are imparted to the screen or screens secured to the container, etc.
[0005] Typically it is desirable to maximize vibration of the screen(s) while isolating equipment, objects, and structures adjacent the vibratory separator from the intense vibrations produced by the vibrating apparatus. Such isolation is effected by using springs, rubber or rubber-like or resilient members or cushions, isolator apparatus, and shock absorbers on which the container or basket is mounted.
[0006] In many vibratory separators and shale shakers parts of the machine are made of steel, e.g. the container basket, housings for vibrating apparatus, vibration isolating springs, and spring mounts. In many environments in which vibratory separators and shale shakers are used, these steel parts are subjected to harsh conditions that result in wear, erosion, rust, and corrosion of the steel. Often shale shakers are used offshore on rigs over salt water. Both the salt environment and the chemicals in drilling fluids processed by the shale shakers can contribute to the deterioration of steel parts.
[0007] In the past parts of screen assemblies and decks for such screens have been made of composite materials; but no prior art suggests that parts of a shale shaker such as the basket, base, or spring mounts be made of composite material, nor does any prior art provide the motivation to do so.
[0008] There has long been a need, recognized by the present inventors, for a vibratory separator and shale shaker with a basket, base, and/or spring mount which resists wear, rust and corrosion. There has long been a need for such machines whose internal vibration can be maximized while effectively isolating objects adjacent the machines from the vibrations. There has long been a need for such machines which are: more cost-effective; relatively lighter in weight and easy to transport either assembled or unassembled; able to withstand material fatigue due to vibration; and/or which are easily repaired.
[0009] The present invention, in certain embodiments, provides a vibratory separator or shale shaker in which a basket, base, and/or spring mount is made of composite material or of metal encased in and/or coated with composite material.
[0010] In certain aspects, the present invention discloses vibratory separators and shale shakers with some parts and components made of composites which are shipped and transported to a job site and assembled at the site. In certain particular aspects, parts are adhesively bonded together or welded together. In one particular aspect parts made of particular types of composite are electromagnetically welded together either at a manufacturing facility or at a job site, e.g., at a drilling rig.
[0011] In certain embodiments, the present invention discloses vibratory separators and shale shakers in which composite (in one aspect relatively flexible composite) material is used in spring mounts to enhance the vibration isolation accomplished by the spring mounts. Walls and/or sides of a basket of a shaker can, according to the present invention, be made of composite material or can have areas made of such composite material (which in one aspect is relatively flexible composite) as can spring mounting brackets or parts.
[0012] Separators and shakers according to the present invention are useful for treating drilling fluid with drilled cuttings and/or with lost circulation material therein, which, in one aspect, includes fibrous lost circulation material and which may be, but is not limited to, any lost circulation material disclosed in or referred to in pending U.S. application Ser. No. 09/975,075 filed Oct. 11, 2001 and co-owned with the present invention and incorporated fully herein for all purposes.
[0013] What follows are some of, but not all, the objects of this invention. In addition to the specific objects stated below for at least certain preferred embodiments of the invention, other objects and purposes will be readily apparent to one of skill in this art who has the benefit of this invention's teachings and disclosures.
[0014] It is, therefore, an object of at least certain preferred embodiments of the present invention to provide new, useful, unique, efficient, nonobvious vibratory separators and shale shakers in which baskets, bases, and/or vibration isolator mounts, are made of composite material, of metal encased in composite material, and/or of metal coated with composite material;
[0015] Such machines in which the screen(s) used for separating material components are effectively vibrated while objects adjacent the machines are not detrimentally vibrated or such vibration is reduced by employing isolator apparatus parts, components and structural members made of composite material and, in one particular aspect, such parts, etc. made of relatively flexible composite material;
[0016] Such machines that are transportable unassembled and are easily assembled at a job site;
[0017] Such machines with such parts that are easily repaired;
[0018] Such machines useful for treating drilling fluid with drilled cuttings and/or with lost circulation material therein, which, in one aspect, includes fibrous lost circulation material; and
[0019] Methods for using such machines.
[0020] Certain embodiments of this invention are not limited to any particular individual feature disclosed here, but include combinations of them distinguished from the prior art in their structures and functions. Features of the invention have been broadly described so that the detailed descriptions that follow may be better understood, and in order that the contributions of this invention to the arts may be better appreciated. There are, of course, additional aspects of the invention described below and which may be included in the subject matter of the claims to this invention. Those skilled in the art who have the benefit of this invention, its teachings, and suggestions will appreciate that the conceptions of this disclosure may be used as a creative basis for designing other structures, methods and systems for carrying out and practicing the present invention. The claims of this invention are to be read to include any legally equivalent devices or methods which do not depart from the spirit and scope of the present invention.
[0021] The present invention recognizes and addresses the previously-mentioned problems and long-felt needs and provides a solution to those problems and a satisfactory meeting of those needs in its various possible embodiments and equivalents thereof. To one skilled in this art who has the benefits of this invention's realizations, teachings, disclosures, and suggestions, other purposes and advantages will be appreciated from the following description of preferred embodiments, given for the purpose of disclosure, when taken in conjunction with the accompanying drawings. The detail in these descriptions is not intended to thwart this patent's object to claim this invention no matter how others may later disguise it by variations in form or additions of further improvements.
[0022] A more particular description of embodiments of the invention briefly summarized above may be had by references to the embodiments which are shown in the drawings which form a part of this specification. This drawings illustrate certain preferred embodiments and are not to be used to improperly limit the scope of the invention which may have other equally effective or legally equivalent embodiments.
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[0032] FIGS.
[0033] FIGS.
[0034] The brackets
[0035]
[0036] According to the present invention, the basket
[0037]
[0038] According to the present invention, the base frame
[0039]
[0040] According to the present invention, the base
[0041] FIGS.
[0042] Tensioning arrangement
[0043] The screen
[0044] The various parts and components of the separator
[0045] U.S. Pat. No. 4,420,391 (fully incorporated herein for all purposes) discloses a separator similar to the separator
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[0047] Portions
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[0050] According to the present invention, the base
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[0055] “Composite” material as used herein includes fiberglass material and other non-metallic composite materials of sufficient strength and rigidity to serve as the listed parts, according to the present invention, of shale shakers, including, but not limited to, the composite materials referred to in U.S. Pat. Nos. 6,335,101; 6,346,425; 6,352,779; 6,343,038; 6,355,206; 6,355,358; 6,361,860; 6,324,833; 6,324,833; and 6,358,603 and in the references cited in these patents—all fully incorporated here for all purposes. It is within the scope of the present invention to use for a part for a shale shaker (parts listed or mentioned above according to the present invention) a composite material with reinforcing wires, bars, cables, pieces, plates, rods and/or discs which are metal, wood or plastic and with and/or within a matrix of cement, fiberglass, and/or plastic, including, but not limited to, as disclosed in U.S. Pat. No. 6,358,603 and in the references referred to in this patent, all of which are incorporated fully herein for all purposes.
[0056] The present invention in at least, but not necessarily all, embodiments, therefore, provides a vibratory separator or a shale shaker with a base, vibration isolation apparatus on the base, a basket, mount apparatus for mounting the basket on the base, and at least one of the base, the basket, and the mount apparatus made of, encased in, or coated with composite material. Such a separator or shaker may have one or some, in any possible combination, of the following: wherein the composite material is non-metal composite material; wherein the composite material includes at least a portion thereof made of flexible composite material or is substantially all flexible composite material; wherein the composite material includes at least one reinforcing part within the composite material; wherein the reinforcing part is made of metal; wherein the reinforcing part is made of material from the group of wood, plastic, fiber, and composite material; electronic tracking apparatus on the shale shaker or separator which may, optionally, be coated with, encased in, or with a housing made of composite material; the basket with a plurality of interconnected walls, the walls connected by electromagnetic welding; the shale shaker or separator has a screen support apparatus and vibratory apparatus for vibrating the screen support apparatus, and isolation apparatus for isolating the screen support apparatus to inhibit vibrations vibrating the screen apparatus from vibrating objects other than the screen support apparatus and the screen apparatus; mounting apparatus to which is mounted the isolation apparatus, the mounting apparatus made from, encased in or coated with composite material; wherein the mounting apparatus includes at least a portion made from, encased in or coated with flexible composite material; wherein the at least a portion of flexible composite material is a plurality of spaced-apart amounts of flexible composite material; wherein the mounting apparatus is made from flexible composite material; wherein the isolation apparatus is a plurality of spaced-apart isolation apparatuses; wherein the isolation apparatus is from the group of springs, resilient members, cushions, flexible hollow members, and inflatable members; wherein the isolation apparatus is coated with composite material; wherein the isolation apparatus is encased in composite material; mounting apparatus to which is mounted the isolation apparatus, the mounting apparatus coated with composite material; mounting apparatus to which is mounted the isolation apparatus the mounting apparatus encased in composite material; wherein the basket includes a plurality of interconnected walls; and/or wherein the shale shaker is for treating fluid introduced thereto, the fluid to be treated including fluid with drilled cuttings therein and/or the fluid to be treated including lost circulation material which, in one aspect, includes fibrous lost circulation material. The present invention in at least, but not necessarily all, embodiments, therefore, provides a method for using any such separator or shaker.
[0057] In conclusion, therefore, it is seen that the present invention and the embodiments disclosed herein and those covered by the appended claims are well adapted to carry out the objectives and obtain the ends set forth. Certain changes can be made in the subject matter without departing from the spirit and the scope of this invention. It is realized that changes are possible within the scope of this invention and it is further intended that each element or step recited in any of the following claims is to be understood as referring to all equivalent elements or steps. The following claims are intended to cover the invention as broadly as legally possible in whatever form it may be utilized. The invention claimed herein is new and novel in accordance with 35 U.S.C. § 102 and satisfies the conditions for patentability in § 102. The invention claimed herein is not obvious in accordance with 35 U.S.C. § 103 and satisfies the conditions for patentability in § 103. This specification and the claims that follow are in accordance with all of the requirements of 35 U.S.C. § 112. The inventor may rely on the Doctrine of Equivalents to determine and assess the scope of their invention and of the claims that follow as they may pertain to apparatus not materially departing from, but outside of, the literal scope of the invention as set forth in the following claims.