Abstract: The invention provides a porous hybrid matrix membrane support having at least one porous mesh layer of mesh densified to form a membrane mesh support and at least one porous filament layer of filaments that are generally non-woven, densified to form a membrane filament support. The filament layer is densified to provide a sufficiently small crevice depth in the membrane filament support that can help protect a membrane layer on the membrane filament support from rupturing. The membrane mesh support and the membrane filament support with micro-smooth surfaces can be integrally joined by diffusion bonding to resist separation across the adjoining surfaces. The combined, diffusion bonded support of both types of layers provide structural support sufficient for high pressures and provide substantial uniform permeability across the face of the structural support.

Abstract: There is provided a wellbore screen having a base pipe and a strip of filter medium wrapped around the base pipe. The strip of filter medium includes one or more layers of woven steel mesh of various weave patterns, fibers sizes, and/or thread tensions. During the construction of the screen, the strip is wrapped around the base pipe under high tension. The strip has two lengthwise edges that may overlap to form a bonded interface.

Abstract: A technique is provided for creating a well screen having a diffusion layer affixed to a filter medium to create a coherent structure. The diffusion layer is formed as a structure that freely allows movement of fluid, while the filtering medium is designed to filter particulates of a specific size. The diffusion layer is affixed to the filtering medium along a filtering medium surface to greatly improve collapse and burst resistance of the filtering medium. One method of affixing comprises bonding the diffusion layer to the filtering medium via a sintering process.