Static mixer assembly, and related manufacturing and usage methods.

Abstract

Disclosed herein are static mixer assemblies and related methods of manufacture and use. The present disclosure provides advantageous static mixer assemblies and improved systems / methods for utilizing and / or manufacturing static mixer assemblies. The present disclosure provides static mixer assemblies manufactured at least in part by additive manufacturing (e.g., via a 3D printing process such as a fused deposition modeling ("FDM") process), and related methods of use. The static mixer assemblies of the present disclosure may be particularly well suited for applications such as, but not limited to, high performance liquid chromatography ("HPLC") applications. The additive manufacturing or 3D printing processes (e.g., FDM or LAMT techniques) described herein can be used to fabricate static mixer assemblies having complex shapes / designs (and, for example, highly effective but small features).

Description

Technical Field

[0001] Cross - reference to Related Applications This application claims priority to U.S. Provisional Patent Application No. 63 / 112,874, filed on November 12, 2020, the entire contents of which are hereby incorporated by reference in their entirety.

[0002] This disclosure relates to static mixer assemblies, and related manufacturing and use methods, and more particularly, to static mixer assemblies at least partially manufactured by additive manufacturing (e.g., via a 3D printing process such as a fused deposition modeling (「FDM」) process).

Background Art

[0003] Generally, static mixer assemblies are used in a variety of engineering applications for the continuous mixing, dispersion, reaction, heating, and / or cooling of fluid materials. These static mixer assemblies are stationary (thus, 「static」) and are typically used as in - line components that operate via the energy of the flow stream in which they are used. For example, without limitation, static mixer assemblies may be used to process liquids, gases, liquid / solid mixtures, and / or supercritical fluids and their mixtures by changing viscosity, (pH level), volumetric flow rate, and / or physical properties.

[0004] Conventional static mixer assemblies may include one or more mixing elements located within a tubular housing placed in a flow path containing the fluids to be mixed. For example, a static mixer assembly may include a single mixing element of a preferred shape, such as an elongated helical structure, as described and disclosed in U.S. Patent No. 7,325,970, which is entirely incorporated herein by reference. In other examples, a static mixer assembly may include individual mixing elements stacked in sequence at various angles, such as the planar mixing element described and disclosed in U.S. Patent No. 6,637,928, which is entirely incorporated herein by reference. Other static mixer assemblies are described and disclosed in U.S. Patent No. 10,661,237, which is entirely incorporated herein by reference.

[0005] Static mixer assemblies are often used in high-performance liquid chromatography (HPLC) applications. HPLC is a form of column chromatography in which the sample is placed in a solvent and pumped through a column housing at high pressure (e.g., above 600 bar) or has a chromatographic packaging material. The sample is transported by a moving carrier fluid stream or mobile phase (and interacts with the packaging material, or stationary phase) so that compounds within the sample can be separated and subsequently identified and quantified. HPLC often utilizes two or more different solvents (as mobile phases) into which the sample to be analyzed is injected. For the desired high accuracy of the HPLC process, the solvents should be thoroughly and homogeneously mixed for maximum instrument performance (e.g., these solvents may be mixed in gradient to improve process throughput by changing the affinity levels of the sample components to the mobile phase). For example, incomplete solvent mixing can result in a degraded HPLC chromatogram, which may then result in excessive baseline noise (e.g., manifested by periodic ripple of the detector signal with respect to time) and / or insufficient peak shape (e.g., manifested by broad and / or asymmetric peak widths). The wetting path materials in these mixers can play a crucial role in both sample binding and reactivity. Generally, inert wetting materials may be preferable because they reduce interaction with the sample, allowing for more accurate readouts by downstream detectors.

[0006] There is interest in improved static mixer assemblies, as well as related manufacturing and usage methods.

[0007] These and other inefficiencies and opportunities for improvement are addressed and / or overcome by the assemblies, systems, and methods of this disclosure. [Overview of the Initiative]

[0008] This disclosure provides advantageous static mixer assemblies, as well as improved systems / methods for utilizing and / or manufacturing static mixer assemblies. More specifically, this disclosure provides static mixer assemblies at least partially manufactured by additive manufacturing (e.g., via a 3D printing process such as an FDM process), and associated methods of use.

[0009] This disclosure relates to a static mixer assembly, comprising a mixer body extending from a first end to a second end, the first end having a first opening, the second end having a second opening, the mixer body comprising a first end member, a mixer portion, and a second end member, the mixer portion having an internal mixer section, the first opening extending inward toward the mixer portion and in fluid communication with a first flow channel, the second opening extending inward toward the mixer portion and in fluid communication with a second flow channel, the first flow channel extending from the first opening to a first manifold positioned proximal to the first end of the internal mixer section, and the second flow channel extending from the second opening to the internal mixer The present invention provides an assembly comprising: a mixer body, the internal mixer section defining a lumen having an outer wall, the internal mixer section extending to a second manifold positioned proximal to the second end of the sursection; and a plurality of first, second, and third grid members positioned within the lumen, the grid members of the first, second, and third grid members each extending across the lumen from one side of the outer wall to another side of the outer wall, wherein the first and third grid members are similarly positioned or oriented across the lumen, thereby creating longitudinal mixing channels and transverse openings within the lumen with respect to the first, second, and third grid members.

[0010] The disclosure also relates to a method for manufacturing a static mixer assembly, providing a mixer body extending from a first end to a second end, wherein the first end has a first opening, the second end has a second opening, and the mixer body includes a first end member, a mixer portion, and a second end member, the mixer portion having an internal mixer section, the first opening extending inward toward the mixer portion and in fluid communication with a first flow channel, the second opening extending inward toward the mixer portion and in fluid communication with a second flow channel, the first flow channel extending from the first opening to a first manifold positioned proximal to the first end of the internal mixer section, and the second flow channel The method provides providing a flannel that extends from a second opening to a second manifold positioned proximal to the second end of an internal mixer section, the internal mixer section defining a lumen having an outer wall, and positioning a plurality of first, second, and third grid members within the lumen, wherein the grid members of the first, second, and third plurality of grid members each extend across the lumen from one side of the outer wall to another side of the outer wall, the first and third plurality of grid members being similarly positioned or oriented across the lumen, thereby creating longitudinal mixing channels and transverse openings within the lumen with respect to the first, second, and third plurality of grid members.

[0011] The above and other features are illustrated by the following diagrams and detailed explanations. Any combination or permutation of embodiments is conceivable. Further advantageous features, functions, and applications of the assemblies, systems, and methods disclosed in this disclosure will become apparent from the following description, particularly when read in conjunction with the accompanying drawings. All references listed in this disclosure are incorporated herein by reference in their entirety.

[0012] The following diagram shows an exemplary embodiment in which similar elements are numbered similarly. The features and aspects of the embodiments are described below with reference to the attached drawings, and the elements are not necessarily drawn to scale.

[0013] Exemplary embodiments of this disclosure are further described with reference to the accompanying drawings. It should be noted that various features, steps, and combinations of features / steps described below and illustrated in the drawings may be arranged and organized differently to result in embodiments that still fall within the scope of this disclosure. Refer to the accompanying drawings to assist those skilled in the art in the preparation and use of the disclosed assemblies, systems, and methods. [Brief explanation of the drawing]

[0014] [Figure 1] This is a side perspective view of an exemplary static mixer assembly as described herein. [Figure 2] Figure 1 is a cross-sectional side perspective view of the static mixer assembly. [Figure 3] This is a partial exploded view of Figure 2. [Figure 4] This is an exemplary side perspective view of an end member. [Figure 5] This is an exemplary side perspective view of an end member. [Figure 6] This is an exemplary partial side perspective view of an internal mixer section. [Figure 7] This is an exemplary partial side perspective view of an internal mixer section. [Figure 8] This is a partial front view of an exemplary internal mixer section. [Figure 9] This is an exemplary partial side perspective view of an internal mixer section. [Figure 10] This is a partial front view of an exemplary internal mixer section. [Figure 11] Another exemplary static mixer assembly as described herein. [Figure 12] Another exemplary static mixer assembly as described herein. [Figure 13] Another exemplary static mixer assembly as described herein. [Figure 14] Another exemplary static mixer assembly as described herein. [Figure 15]A side perspective view of the static mixer assembly of FIG. 14 after the mixer body is housed in the housing member. [Figure 16] A side perspective view of the static mixer assembly of FIG. 15. [Figure 17] A side view of the static mixer assembly of FIG. 16. [Figure 18] A side perspective view of the mixer portion of the static mixer assembly of FIG. 14. [Figure 19] A side perspective view of the mixer portion of the static mixer assembly of FIG. 14. [Figure 20] An end view of the mixer portion of the static mixer assembly of FIG. 14. [Figure 21] An end view of another exemplary static mixer assembly according to the present disclosure. [Figure 22] A cross-sectional view of the exemplary static mixer assembly of FIG. 21. [Figure 23] A chart showing the time and temperature profile of an exemplary mixer body.

MODE FOR CARRYING OUT THE INVENTION

[0015] The exemplary embodiments disclosed herein illustrate the advantageous static mixer assemblies, and systems, and methods / techniques thereof of the present disclosure. However, it should be understood that the disclosed embodiments are merely examples of the present disclosure that can be embodied in various forms. Accordingly, the details disclosed herein with reference to the exemplary static mixer assemblies and the associated processes / techniques of manufacture / assembly and use are not limiting, but rather should be construed as a basis for teaching those skilled in the art how to make and use the advantageous static mixer assemblies and / or alternative static mixer assemblies of the present disclosure.

[0016] The present disclosure provides advantageous static mixer assemblies and improved systems / methods for utilizing and / or manufacturing static mixer assemblies.

[0017] More specifically, the present disclosure provides a static mixer assembly at least partially manufactured by additive manufacturing (e.g., via a 3D printing process such as an FDM process), and related methods of use.

[0018] The static mixer assemblies of this disclosure may be particularly well suited to applications such as high-performance liquid chromatography (HPLC) applications, but are not limited to these.

[0019] Here, referring to the drawings, similar parts are marked with the same reference number throughout the specification and the drawings. The drawings are not necessarily to scale, and in certain views, parts may be exaggerated for clarity.

[0020] As shown in Figure 1, an exemplary static mixer assembly 10 includes a mixer body 12 extending from a first end 11 to a second end 13. The first end 11 includes a first opening 15, and the second end 13 includes a second opening 17 (Figure 2).

[0021] In exemplary embodiments, as will be further described below, at least a portion of the mixer body 12 is manufactured by additive manufacturing (for example, via a 3D printing process such as a fused deposition modeling ("FDM") process).

[0022] It should be noted that at least a portion of the exemplary mixer body 12 of this disclosure may be manufactured / printed via additive manufacturing or 3D printing processes. In exemplary embodiments, at least a portion of the mixer body 12 is manufactured / printed using a fused filament method or fused deposition modeling ("FDM") process, but this disclosure is not limited thereto.

[0023] Generally speaking, fused deposition modeling (FDM) is a 3D printing process. FDM is an additive manufacturing method in which a filament (e.g., thermoplastic polymer filament) is fed into a heated nozzle, and the molten polymer is extruded from this nozzle as a very fine extrusion. Generally, the smaller the nozzle used, the higher the final resolution, but the printing time can be very long. A typical nozzle diameter is 0.4 mm, but it can generally be as small as 0.2 mm and as large as 1 mm. The nozzle is typically mounted in an xyz gantry system at the nozzle height relative to the xy axis table, and the xy axis table is precisely controlled via a stepper or servo motor. The CAD model of the part to be manufactured / printed (e.g., mixer body 12) is sliced ​​into fine layers along the z (vertical) axis, and the computer controls the relative position of the extrusion nozzle to the xy table to print one layer of that part at a time. The extruder is turned on, and the computer moves the xy table axes to deposit the first layer of the model onto the build plate. Once the first layer is deposited, the vertical axis (z) is adjusted to the next layer, and the process is repeated until the entire volume of the part is manufactured / printed. The nozzle temperature is set to the melting temperature of the polymer used for printing, and can generally range from about 190°C for low-performance polymers (e.g., polylactide or PLA polymers), 265°C for medium-performance polymers (e.g., nylon), to 420°C for high-performance polymers (e.g., polyetheretherketone or PEEK). The bed on which the part is printed can be at ambient temperature for low-performance polymers such as PLA, and is usually heated to 200°C for high-performance polymers such as PEEK. The air temperature may be heated to promote interlayer adhesion and is often required for high-performance polymers such as PEEK to prevent cracking of the part during cooling / solidification. Generally, FDM is not a fast process, and larger, more complex parts (e.g., engine blocks) can take several days to print, while small parts like penny-sized parts can be printed in minutes.In some embodiments, it may take 2 to 4 hours to manufacture / print one of the exemplary mixer bodies 12 (e.g., PEEK mixer body 12) using the current design.

[0024] The exemplary printer used to manufacture / print the exemplary mixer body 12 (e.g., PEEK mixer body 12) is a Creatbot F430. In certain embodiments, this printer was modified to print the exemplary mixer body 12 by adding an additional heater that allows the build plate to be heated to 200°C. For the exemplary Creatbot F430 printer, the maximum extruder temperature was 420°C, the maximum bed temperature was 110 / 200°C, the maximum air temperature was 110°C, the print bed size was 300mm x 400mm, and the print height was 300mm.

[0025] It should be noted that in other embodiments of this disclosure, at least a portion of the mixer body 12 may be manufactured using laser additive manufacturing ("LAMT"). As used herein, additive manufacturing refers to a 3D printing process in which continuous layers of material are formed to create an object of a desired shape. Laser additive manufacturing, or LAMT, refers to an additive manufacturing technique that uses a laser to melt, soften, sinter, or otherwise affect the material used in the object being manufactured. By varying the specifications and conditions of the material and the manufacturing process, a desired mixer body 12 can be manufactured.

[0026] The laser used may include any suitable laser, such as pulsed carbon dioxide. Generally, the laser scans across the surface of a first layer of particle bed placed on a build plate to melt or sinter particles, followed by subsequent laser scanning and application of another layer of particles for melting or sintering. Multiple subsequent layers are created as the laser scans across the bed, and layers of particles are applied as needed to create a product (e.g., mixer body 12).

[0027] The materials used in this disclosure for LAMT are materials provided in a granular form that can be sintered, partially melted, or completely melted by the laser used in the laser additive manufacturing technique. Note that various polymer materials may be used in the laser additive manufacturing technique for manufacturing and printing the exemplary mixer body 12.

[0028] The additive manufacturing or 3D printing processes described herein (e.g., FDM or LAMT technologies) may be used to fabricate mixer bodies 12 having complex shapes / designs (and, for example, being very effective but small in size). Generally, and without wishing to be constrained by theory, the small, unique, complex shapes / designs of the mixer bodies 12 of this disclosure that can be fabricated using additive manufacturing or 3D printing processes (e.g., FDM or LAMT technologies) result in complex fluid flow patterns that lead to more thorough mixing in a smaller internal volume compared to conventional mixers. As a result, smaller-sized mixer assemblies 10 may be used for the complete mixing of multiple fluids. Thus, the static mixer assemblies 10 of this disclosure may be particularly well suited to applications such as HPLC, but are not limited to these.

[0029] Referring here to Figures 1-3, the exemplary mixer body 12 includes a first end member 20A, a mixer portion 30, and a second end member 20B. Note that in certain embodiments, the end members 20A and 20B are essentially mirror images of each other and are positioned at 180 degrees relative to each other and to the mixer portion 30.

[0030] The first opening 15 of the first end member 20A extends inward (for example, toward the mixer section 30) and is in fluid communication with the first flow channel 16. Similarly, the second opening 17 of the second end member 20B extends inward (for example, toward the mixer section 30) and is in fluid communication with the second flow channel 18. Generally, the first flow channel 16 is smaller (for example, in diameter) than the first opening 15, and the second flow channel 18 is smaller (for example, in diameter) than the second opening 17. The first and second flow channels 16, 18 can take the form of capillary tubes or the like, but are not limited to this disclosure. Generally, the first flow channel 16 (or the second flow channel 18) is configured and sized to deliver a fluid (for example, an HPLC fluid) to the internal mixer section 36 of the mixer section 30 described below.

[0031] The first flow channel 16 extends from the first opening 15 to the first manifold 22A of the end member 20A. The second flow channel 18 extends from the second opening 17 to the second manifold 22B of the end member 20B.

[0032] Generally, each manifold 22A, 22B is positioned near the mixer section 30. Generally, each manifold 22A, 22B includes one or more wedge members 32 (e.g., multiple wedge members 32). The wedge members 32 extend from or are positioned near the inner walls 34A, 34B.

[0033] It should be noted that the inner walls 34A and 34B of each manifold 22A and 22B may be angled with respect to the plane of the ends 11 and 13 (for example, they may be angled at about 10 degrees). In an exemplary embodiment, the location where the first flow channel 16 meets manifold 22A creates a fluid mixing point, and the location where the second flow channel 18 meets manifold 22B creates a fluid mixing point.

[0034] In exemplary embodiments, manifold 22A is positioned near the outer circumference (e.g., outer diameter) of the first end 31 of the internal mixer section 36 of the mixer portion 30, and manifold 22B is positioned near the outer circumference (e.g., outer diameter) of the second end 33 of the internal mixer section 36 of the mixer portion 30. Generally, manifold 22A (or manifold 22B) is configured and dimensional to distribute the fluid flow over an area (e.g., a larger area) of the internal mixer section 36.

[0035] In some embodiments, the outer circumference (e.g., outer diameter) of manifold 22A is substantially the same size as the outer circumference (e.g., outer diameter) of the first end 31 of the internal mixer section 36, and the outer circumference (e.g., outer diameter) of manifold 22B is substantially the same size as the outer circumference (e.g., outer diameter) of the second end 33 of the internal mixer section 36.

[0036] In an exemplary embodiment, the internal mixer section 36 of the mixer unit 30 extends from a first end 31 to a second end 33 (Figure 3) and defines a lumen 38 (e.g., a cylindrical lumen 38) having an outer wall 40.

[0037] As will be further described below, a plurality of grid members 42 are positioned within the lumen 38, and the grid members or rods 42 generally extend across the lumen 38 from one side of the wall 40 to another side of the wall 40. In exemplary embodiments, the plurality of grid members or rods 42 extend from a first end 31 to a second end 33 of the internal mixer section 36, but the disclosure is not limited thereto.

[0038] Generally, the wedge members 32 of the manifolds 22A and 22B are configured and sized to provide support to the outermost grid members 42 at the ends 31 and 33 of the internal mixer section 36 (for example, particularly during the additive manufacturing or 3D printing process of the mixer body 12).

[0039] As shown in Figures 2, 3 and 6-10, a plurality of grid members or rods 42 (e.g., 42A, 42B, 42C, etc.) are positioned within the lumen 38, and the grid members or rods 42 generally extend across the lumen 38 from one side of the wall 40 to another side of the wall 40, and the plurality of grid members or rods 42 extend from the first end 31 to the second end 33 of the internal mixer section 36.

[0040] In exemplary embodiments, it should be noted that during the fabrication / manufacturing of the mixer body 12 (e.g., via additive manufacturing or a 3D printing process), the manufacturing of the mixer body 12 can be started from either end 11 or end 13 of the mixer body 12.

[0041] For example, when the manufacturing of the mixer body 12 (e.g., via additive manufacturing or a 3D printing process) begins at the end 11, the first end member 20A is manufactured first until the time comes when the manufacturing of the mixer section 30 begins.

[0042] As shown in Figure 7, the internal mixer section 36 of the mixer section 30 is then manufactured, starting at the first end 31 of the internal mixer section 36. The manufacturing of the outer wall 40 that ultimately defines the lumen 38 can then be started, and a first plurality of grid members 42A positioned proximal to the first end 31 can be manufactured, with each grid member 42A extending from one side of the wall 40 to another side of the wall 40 (Figures 7-8).

[0043] For example, as shown in Figures 7-8, the first plurality of grid members 42A positioned proximal to the first end 31 may include five grid members 42A, the grid members 42A extending horizontally from the side of the wall 40 across the lumen 38. Note that the first plurality of grid members 42A may include various numbers of grid members 42A (e.g., one or more grid members 42A, two, three, four, six, etc.). Also note that the first plurality of grid members 42A may extend from the side of the wall 40 across the lumen 38 in various different ways and / or various different combinations (e.g., vertically, diagonally, some vertical and some horizontally, some vertical and some diagonally, some horizontal and some diagonally, etc.).

[0044] After the first plurality of grid members 42A positioned proximal to the first end 31 have been manufactured, a second plurality of grid members 42B can be manufactured, positioned proximal to the first plurality of grid members 42A and positioned within the lumen 38 toward the second end 33 (Figures 9 and 10).

[0045] In exemplary embodiments, as shown in Figures 9-10, the second plurality of grid members 42B may include five grid members 42B, the grid members 42B extending vertically from the side of the wall 40 across the lumen 38.

[0046] It should be noted that the second set of grid members 42B may include various numbers of grid members 42B (e.g., one or more grid members 42B, two, three, four, six, etc.). It should also be noted that the second set of grid members 42B may extend from the sides of the wall 40 across the lumen 38 in various different ways and / or various different combinations (e.g., vertically, diagonally, some vertical and some horizontally, some vertical and some diagonally, some horizontal and some diagonally, etc.).

[0047] As shown in Figures 9 and 10, each grid member 42A, 42B is connected to two sides of the wall, and each grid member 42A is connected to or positioned proximal to one or more grid members 42B.

[0048] After the second set of grid members 42B has been manufactured, a third set of grid members 42C can be manufactured, which are positioned proximal to the second set of grid members 42B and positioned within the lumen 38 toward the second end 33 (Figure 6).

[0049] In exemplary embodiments, the third plurality of grid members 42C may include five grid members 42C, the grid members 42C extending horizontally from the side of the wall 40 across the lumen 38 (similar to, for example, grid member 42A).

[0050] It should be noted that the third plurality of grid members 42C may include any number of grid members 42C, and that the third plurality of grid members 42C may extend from the side of the wall 40 across the lumen 38 in various different ways and / or in various different combinations, as described above.

[0051] Generally, each grid member 42C is connected to two sides of the wall, and each grid member 42C is connected to or positioned proximal to one or more grid members 42B.

[0052] After the third set of grid members 42C has been manufactured, a fourth set of grid members 42D can be manufactured, which are positioned proximal to the third set of grid members 42C and positioned within the lumen 38 toward the second end 33 (Figure 6).

[0053] In an exemplary embodiment, the fourth plurality of grid members 42D may include five grid members 42D, the grid members 42D extending perpendicularly from the side of the wall 40 across the lumen 38 (similar to, for example, grid member 42B).

[0054] The fourth set of grid members 42D may include any number of grid members 42D, as described above, and it should be noted that the fourth set of grid members 42D may extend from the side of the wall 40 across the lumen 38 in various different ways and / or in various different combinations, as described above.

[0055] Generally, each grid member 42D is connected to two sides of the wall, and each grid member 42D is connected to or positioned proximal to one or more grid members 42C.

[0056] This manufacturing process can then be repeated over the length of the lumen from the first end 31 to the second end 33 (for example, after manufacturing grid member 42D, grid member 42E can be manufactured, then grid member 42F can be manufactured, then grid member 42G can be manufactured, and so on).

[0057] In exemplary embodiments, as shown in Figure 3, all other grid members 42 are positioned or oriented in the same or similar manner across the lumen 38 (for example, grid members 42A, 42C, and 42E are oriented or positioned to extend horizontally across the lumen 38 from the side of the wall 40, and grid members 42B, 42D, and 42F are oriented or positioned to extend vertically across the lumen 38 from the side of the wall 40), but the disclosure is not limited thereto.

[0058] In embodiments in which all other grid members 42 are positioned or oriented across the lumen 38 in the same or similar manner, it should be noted that this advantageously forms multiple longitudinal mixing channels 44 through the lumen 38 from the first end 31 to the second end 36 (Figure 10).

[0059] Figure 3 shows details of an exemplary internal mixer section 36. The internal mixer section 36 may include stacked grid members 42A, 42B, etc., all other grid members 42 positioned or oriented in the same or similar manner across the lumen 38 to provide longitudinal mixing channels 44 and also provide openings that traverse the flow direction (e.g., across the flow in the channel 16) to provide fluid mixing (e.g., transverse openings between members 42A and 42C). The pattern of the grid members 42 and the size of the openings, along with the overall diameter and length of the internal mixer section 36, may be adjusted to provide a specific internal volume and mixing efficiency. For example, the diameter of the internal mixer section 36 (e.g., of the lumen 38) may be about 7 mm, and the length of the internal mixer section 36 (e.g., of the lumen 38) may be about 14 mm. Note that the mixing channels 44 may be of different sizes (e.g., opening 44A versus opening 44B in Figure 10).

[0060] In another embodiment, the widths of several grid members 42 (e.g., grid members 42 manufactured from PEEK) are shown, as in Figures 18-20. In this example, the grid members 42 are approximately 0.016 inches (0.4 mm) wide. The through-channel openings of the mixing channels 44C near the center are substantially square in shape, measuring approximately 0.032 inches (0.8 mm) on their sides, while the openings of the mixing channels 44P near the periphery are smaller and not square in shape. The lateral gap openings of these mixing channels 44 are smaller, some approaching 0.008 inches (0.2 mm).

[0061] After all of the multiple grid members 42 have been manufactured (e.g., 42A, 42B, 42C, etc.) and the manufacturing process has reached the second end 33, the second end member 20B can be manufactured until it reaches the second end 13 of the mixer body 12. Note that in other embodiments, the mixer body 12 of the static mixer assembly 10 can be manufactured starting from the second end 13 and reaching the first end 11.

[0062] It should be noted that during the manufacturing of the mixer body 12, the grooves 46 can be manufactured (e.g., printed) on the mixer body 12 (for example, on the outer surfaces of the end members 20A and / or 20B).

[0063] It should be noted that after the manufacture of the mixer body 12, screw threads 48, etc. (Figure 15) can be machined or manufactured on the mixer body 12 (for example, on the proximal surface of the first opening 15 and / or the second opening 17). For example, the screw threads 48 can be 10 to 32 threads configured for an HPLC compression fitting.

[0064] It should also be noted that after the manufacture of the mixer body 12, the flow channels 16 and / or 18 can be further machined and / or manufactured.

[0065] Figure 14 shows another exemplary mixer body 12 (for example, manufactured via FDM and utilizing PEEK), which does not have grooves 46. Some exemplary dimensions of the mixer body 12 in Figure 14 can be approximately 0.612 inches (15.5 mm) × 2.06 inches (51 mm).

[0066] After printing the mixer body 12 shown in Figure 14, the mixer body 12 was annealed in a convection air oven at programmable rising and cooling rates to increase the interlayer strength of the 3D printed portion (e.g., the mixer body 12). Very slow cooling may be required after heat treatment to prevent excessive residual stress within the body 12 and to prevent cracking. A typical annealing / heat treatment temperature profile, where the temperature is expressed as a percentage of the 3D printing temperature of a particular lot of PEEK polymer, is shown in Table 1 below. Printing temperatures typically vary up to 30 degrees depending on the supplier.

[0067] More specifically, each printed mixer body 12 was placed in a heat treatment fixture that radially restrained the mixer body 12 to prevent distortion of the body 12 due to uneven shrinkage, which often occurs during the heat treatment process. Furthermore, a small compressive force was applied axially to the mixer body 12 during heat treatment to aid in increasing interlayer adhesion. For larger areas, it may be necessary to increase this externally applied force, while for very small areas, it may be necessary to decrease the applied force.

[0068] [Table 1]

[0069] After annealing / heat treatment, the mixer body 12 shown in Figure 14 was then coated with epoxy and inserted into the housing 24 (e.g., stainless steel tube 24) and cured (assembly 100 in Figures 15-17). Once the epoxy had cured, the ends of the mixer body 12 and housing 24 were machined flat, and threads 48 (e.g., HPLC fittings) were machined at both ends of the assembly 100 for inlet and outlet connections (e.g., 1 / 16-inch inlet and outlet to the HPLC).

[0070] The exemplary stainless steel tube 24 into which the mixer body 24 was inserted had an inner diameter (ID) of 0.625 inches and an outer diameter (OD) of 0.875 inches. Thus, Figure 16 shows a perspective view of the static mixer assembly 100 (e.g., a 150 μL PEEK mixer body 12 enclosed in a thick-walled stainless steel sleeve 24 to provide an enhanced pressure rating). Note that all wetted surfaces of assembly 100 are manufactured from PEEK, and the mixer body 12 is then enclosed in the thick-walled stainless steel sleeve 24 to provide a pressure rating exceeding a burst pressure of 1200 bar (17,400 psi) (e.g., for HPLC and / or UHPLC applications).

[0071] Some dimensional performance results for this static mixer assembly 100 (e.g., a 150uL PEEK static mixer assembly 100) are shown in Table 2 below. The entire mixer assembly 100 was tested up to a pressure of 1000 bar, and the coupling was tested up to a pressure of 1200 bar, and no leaks were observed. The internal cavity volume of the mixer assembly 100 was in the range of 128–165uL with a target value of 150uL. The mixing efficiency (ripple reduction) of these exemplary assemblies 100 was in the range of 80–85%.

[0072] [Table 2]

[0073] Referring back to Figure 1, note that the mixer body 12 does not necessarily need to have a high-voltage rating, and it may not be necessary to enclose the mixer body 12 in a housing 24 (for example, a stainless steel sleeve 24).

[0074] Figure 1 shows a static mixer assembly 10 (without housing 24). Figure 1 shows a printed mixer body 12 (e.g., PEEK mixer body 12) targeting an internal volume of 250 μL with a pressure rating of 400 bar. Grooves 45 are printed on the surface of the mixer body 12 to facilitate the retention of HPLC fittings while tightening them to their ends. In Figure 1, the mixer body 12 is not heat-treated, and the HPLC fittings have not yet been machined to their ends.

[0075] Figure 11 shows an example of a finished 350 μL mixer body 12' printed with polyether ketone (PEKK) for application to a 400 bar pressure rating. It has a diameter of 1 inch (25 mm) and a length of 2 inches (50 mm), with standard 1 / 16 inch HPLC compression fittings machined to both ends.

[0076] Figure 12 shows an example of a finished 500uL mixer body 12'' printed with PEKK for a 400 bar pressure rating application. It has a diameter of 0.75 inches (19 mm) and a length of 2.5 inches (64 mm), with standard 1 / 16 inch HPLC compression fittings machined to both ends.

[0077] Figure 13 shows an example of a finished 1000uL mixer body printed in PEEK for a 200 bar pressure rating application. The central diameter is 0.75 inches (19 mm), the overall length is 2.35 inches (60 mm), and standard 1 / 16-inch HPLC compression fittings are machined at both ends. The inlet and outlet ends have hexagonal cross-sections, allowing the fittings to be tightened using a tool.

[0078] In another embodiment, as shown in Figures 21 and 22, the static mixer assembly 200 includes a mixer body 12 housed within a housing 24 (e.g., a stainless steel tube 24). The mixer body 12 of the assembly 200 (e.g., a PEEK mixer body 12) may be manufactured as described above.

[0079] However, instead of gluing the mixer body 12 to the housing 24 (e.g., stainless steel sleeve 24), the mixer body 12 can be inserted into the housing 24 (e.g., stainless steel sleeve 24) which has threaded ends 50A, 50B with slip-fits, and then the mixer body 12 can be compressed by screwing caps or nuts 52A, 52B onto both ends 50A, 50B and tightening the end caps 52a, 52b to prevent the mixer body 12 from bursting under high pressure. In addition, the machining of the HPLC fittings of the assembly 200 can differ in that a taper can be machined, 1 / 16 inch pipe ends can be machined onto the mixer body 12, and 10-32 threads 48 for the pipe fittings can be machined onto the stainless steel caps 52A, 52B at both ends of the mixer assembly 200. This improves thread strength and allows the fittings to be tightened to a higher torque level using a wrench to ensure that there are no leaks in the fittings.

[0080] In other embodiments, the internal mixer section 36 is cylindrical in shape with an exemplary diameter of 7.5 mm (0.3 inches) and a length of 13.9 mm (0.55 inches), filled with stacked grid members or rods 42, to achieve a mixing volume of 150 μL for the mixer body 12. For larger mixer volumes, the length and diameter of this internal mixer section 36 can be increased to achieve the desired volume. A 1000 μL mixer body 12 was manufactured using internal volume dimensions of 12.5 mm (0.5 inches) in diameter and 25.4 mm (1 inch) in length. As expected, the external dimensions increase with increasing internal volume and further increase if a higher burst pressure rating is desired.

[0081] The internal mixer section 36 can be filled with stacked layers of grid members / rods 42, each layer of which is parallel to the previous layer and rotated 90 degrees (see, for example, Figures 6 and 10). The diameter of each grid member or rod 42 may be 0.1 mm to 0.25 mm, depending on the desired internal volume, with gaps between the rods 42 ranging from 0.1 mm to 0.4 mm.

[0082] As the fluid passes through the mixer body 12, the fluid can move through channels 44 parallel to the flow direction between rod intersections, and the fluid can move laterally (for example, across the flow direction of channels 16, 18) between the stacked layers of parallel grid members or rods 42. It is this lateral flow that is recombined with the different flow paths, which advantageously results in the improved mixing observed using this mixer body 12 design.

[0083] The mixer body 12 may also be heat-treated after manufacturing / printing in certain embodiments to increase the interlayer adhesion strength, which may be weak when using FDM printing. The mixer body 12 may be gradually heated to a predetermined temperature under axial compression in a convection oven in a nitrogen-rich gas environment, held at that temperature for a predetermined period, and then gradually cooled back to room temperature.

[0084] Note that in some embodiments, stacked rods 42 are printed for each layer rotated 90 degrees from the previous layer. In other embodiments, the mixer body 12 can be printed with these angles being multiples of 45 degrees and random. A pilot run is completed using 90-degree rotations, and the results are shown in Table 3 below. These mixer bodies 12 were printed using an internal mixer section 36 with a diameter of 0.3 inches and a length of 0.55 inches, as described above.

[0085] [Table 3]

[0086] It should be noted that the examples shown so far are primarily for in-line applications where the mixer 12 is placed between two objects with one or more inlet lines attached and one outlet line attached. However, there are applications where it may be desirable to mount the mixer 12 directly to a pump, proportional valve, or other equipment without using tubing and / or compression fittings. When it is desired to reduce the overall size of the HPLC system, it is often desirable to reduce the internal volume of the fluid paths within the system or to save space. One example is replacing a standard 1 / 16-inch 10-32 internal compression fitting (female) with an external 10-32 compression fitting (male), which allows the user to mount the mixer 12 directly to another component within the HPLC instrument without using additional tubing and compression fittings.

[0087] Generally, static mixers are used in HPLC instruments downstream of the pump and on the high-pressure side of the system. If low-pressure mixing (upstream of the pump) is desired, some instrument manufacturers use 1 / 4-28 flat-bottom fittings for these cases, and in such applications, a mixer like the one described above can be fabricated using a 1 / 4-28 flat-bottom fitting instead of the more common 1 / 16-inch 10-32 compression fitting. One example of this is for use in a quaternary pump system where mixer 12 is placed in the fluid path between a proportional valve and a high-pressure pump.

[0088] To reduce the complexity and size of standard HPLC instruments, for example, a proportional valve body with an internal cavity within the fluid path where the mixing element (lumen) is placed in the assembly can be designed, thereby eliminating the need for an external in-line mixer. This has the advantage of reducing the overall size of the instrument and reducing the internal volume of the fluid path, which generally improves system performance. The hardware can be designed so that the mixing element (lumen) can be removed and replaced with a mixer of a different internal volume when necessary.

[0089] Furthermore, in the examples above, the cross-section of the device is round. It should be noted that the cross-section is not limited to a round shape, and any shape / design (e.g., square, hexagon, etc.) can be used (e.g., for aesthetic purposes or to facilitate surface mounting of the mixer 12 when mounted on a fixture). Also, in the examples above, the inlet and outlet to the mixer 12 are parallel to the flow direction through the device. For example, typically, if space may be limited, the inlet and / or outlet can be mounted at an angle (e.g., typically 90 degrees) from the axial direction of the mixer 12 (e.g., to fit the mixer 12 into a smaller space).

[0090] While specific embodiments are described, alternatives, modifications, variations, improvements, and substantial equivalents that are not currently anticipated or cannot be anticipated may arise for the applicant or those skilled in the art. Therefore, the attached claims, which may be filed and amended, are intended to encompass all such alternatives, modifications, variations, improvements, and substantial equivalents.

[0091] The scope disclosed herein includes endpoints, which are independently combinable (for example, the range “up to 25% by weight, or more specifically, 5% to 20% by weight” includes the endpoints and all intermediate values ​​within the “5% to 25% by weight” range). “Combination” includes blends, mixtures, alloys, reaction products, etc. Terms such as “first,” “second,” etc., do not indicate any order, quantity, or importance, but rather are used to distinguish one element from another. The terms “a,” “an,” and “the” do not indicate a limit on quantity and should be interpreted to cover both singular and plural forms unless otherwise indicated herein or explicitly contradicts the context. “Or” means “and / or” unless otherwise specified. Throughout this specification, references to “several embodiments,” “embodiments,” etc., mean that certain elements described in relation to embodiments are included in at least one embodiment described herein and may or may not be present in other embodiments. Furthermore, it should be understood that the elements described may be combined in any preferred manner in various embodiments. “Combinations of ~” is open and includes any combination that optionally includes at least one of the enumerated components or characteristics together with similar or equivalent components or characteristics that are not enumerated.

[0092] Unless otherwise defined, technical and scientific terms used herein have the same meanings as commonly understood by those skilled in the art to which this application belongs. All cited patents, patent applications, and other references are incorporated herein by reference in their entirety. However, if any terminology in this application conflicts with or is in conflict with any terminology in any incorporated reference, the terminology in this application shall prevail over any conflicting terminology from the incorporated reference.

[0093] The systems and methods of this disclosure are described with reference to their exemplary embodiments, but this disclosure is not limited to such exemplary embodiments and / or implementations. Rather, the systems and methods of this disclosure are susceptible to many implementations and applications, as will be readily apparent to those skilled in the art from this disclosure. This disclosure expressly includes such modifications, enhancements, and / or variations of the embodiments disclosed. Since many changes can be made in the above configurations, and many widely different embodiments of this disclosure can be made without departing from its scope, all matters contained in the drawings and specification are intended to be construed as illustrative and not restrictive. Additional modifications, changes, and substitutions are intended in the above disclosure. Accordingly, the appended claims should be construed broadly in a manner consistent with the scope of this disclosure.

Claims

1. A static mixer assembly, A mixer body extending from a first end to a second end, wherein the first end has a first opening, the second end has a second opening, and the mixer body includes a first end member, a mixer portion, and a second end member, the mixer portion having an internal mixer section. The first opening extends inward toward the mixer portion and is in fluid communication with the first flow channel, and the second opening extends inward toward the mixer portion and is in fluid communication with the second flow channel, The first flow channel extends from the first opening to a first manifold positioned near the first end of the internal mixer section, and the second flow channel extends from the second opening to a second manifold positioned near the second end of the internal mixer section. The internal mixer section comprises a mixer body that defines a lumen having an outer wall, A plurality of first, second, and third grid members positioned within the lumen, wherein each of the first, second, and third grid members extends across the lumen from one side of the outer wall to another side of the outer wall, The first and third grid members are positioned or oriented similarly across the lumen, thereby creating longitudinal mixing channels and transverse openings within the lumen for the first, second, and third grid members. A static mixer assembly in which the first and second manifolds each include one or more wedge members.

2. The assembly according to claim 1, wherein each of the first, second, and third grid members includes five grid members.

3. The assembly according to claim 1, further comprising a housing surrounding the mixer body.

4. The assembly according to claim 1, wherein the lumen is a cylindrical lumen.

5. The assembly according to claim 1, wherein the first flow channel has a smaller diameter than the first opening, and the second flow channel has a smaller diameter than the second opening.

6. The assembly according to claim 1, wherein the first and second end members are mirror images of each other.

7. A method for manufacturing a static mixer assembly, To provide a mixer body extending from a first end to a second end, wherein the first end has a first opening, the second end has a second opening, the mixer body includes a first end member, a mixer portion, and a second end member, and the mixer portion has an internal mixer section. The first opening extends inward toward the mixer portion and is in fluid communication with the first flow channel, and the second opening extends inward toward the mixer portion and is in fluid communication with the second flow channel, The first flow channel extends from the first opening to a first manifold positioned near the first end of the internal mixer section, and the second flow channel extends from the second opening to a second manifold positioned near the second end of the internal mixer section. The aforementioned internal mixer section defines and provides a lumen having an outer wall, Positioning a plurality of first, second, and third grid members within the lumen, wherein each of the first, second, and third grid members extends across the lumen from one side of the outer wall to another side of the outer wall, The first and third grid members are positioned or oriented similarly across the lumen, thereby creating longitudinal mixing channels and transverse openings within the lumen for the first, second, and third grid members. A method wherein the first and second manifolds each include one or more wedge members.

8. The method according to claim 7, wherein the mixer body is manufactured at least partially by additive manufacturing.

9. The method according to claim 7, wherein the mixer body is manufactured at least partially by a 3D printing process.

10. The method according to claim 7, wherein the mixer body is at least partially manufactured by a fused deposition modeling (FDM) process.

11. The method according to claim 8, wherein the mixer body is heat-treated after manufacturing.

12. The method according to claim 7, wherein the mixer body is at least partially manufactured from polyetheretherketone.

13. The method according to claim 7, further comprising providing a housing surrounding the mixer body.

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