Cogged Mixing Element Spoke Segmentation for Homogeneity
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Solution Overview
Problem
The mixing of medical, pharmaceutical, or cosmetic products with different consistencies, densities, and viscosities often results in uneven mixing behavior, leading to longer processing times and potential thermal degradation of heat-sensitive components, which increases costs and reduces efficiency.
Innovation Solution
A mixing element with a hub and annular stirring part carrier featuring stirring teeth on the outer peripheral side and spoke elements for improved mixing, generating additional partial flows and effectively detaching components from the vessel walls, allowing for efficient mixing of diverse product components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional mixing discs with radial webs are used, then the structure is simple and easy to manufacture, but mixing homogeneity deteriorates due to uneven distribution of components with different densities and viscosities
Solution Approach 1:
The mixing element is segmented into multiple functional components: a hub, multiple spoke elements extending radially outward, and a stirring part carrier at the periphery. Each spoke element independently connects the hub to the stirring part carrier, creating multiple pathways for material flow and enhancing mixing homogeneity by distributing shear forces throughout the mixture.
Solution Approach 2:
Different regions of the mixing element are designed with different properties: the hub provides central support and torque transmission, the spoke elements create radial flow patterns and partial mixing zones, and the peripheral stirring part carrier handles bulk material movement. This local differentiation optimizes mixing efficiency for components with varying densities and viscosities.
2Manufacturing precision
If mixing time is extended to achieve homogeneous mixing of components with different properties, then mixing quality improves, but thermal degradation of heat-sensitive components occurs and productivity decreases
Solution Approach 1:
The mixing element is designed to create dynamic flow patterns through its rotating spokes and peripheral carrier. The rotation generates continuous radial and tangential flows that rapidly distribute components throughout the mixture, achieving homogeneity faster and reducing the risk of thermal degradation in heat-sensitive materials.
3Productivity
If simple radial web connections are used between hub and stirring part, then the structure is simple, but mixing effectiveness deteriorates due to inadequate handling of components with varying densities
Solution Approach 1:
The connection between the hub and stirring part carrier is segmented into multiple discrete spoke elements rather than using simple radial webs. These spoke elements are distributed around the circumference and independently connected to both the hub and the peripheral carrier, creating multiple mixing zones and improving the handling of components with varying densities and viscosities.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The mixing element ensures quick and efficient homogenization of products, reducing processing time and maintaining product quality by effectively handling components with varying properties.
Implementation Method 1
By providing the stirring teeth on the outer peripheral side of the stirring part carrier, additional partial flows are generated in addition to the mixed flow generated overall by the mixing element
Implementation Method 2
Due to the different density and viscosity of the individual components of the mixture to be mixed, the individual components and any suspended particles with a high density or high viscosity tend to move to the outer edge area of the mixing or stirring vessel during the mixing process, i.e. away from the inner area between the stirring part and the drive shaft. In contrast, the mixture components and any suspended particles with a low density or low viscosity tend to move into the inner area between the stirring part and the hub
Data Source
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AI summary
A mixing element (10) for mixing medical, pharmaceutical, or cosmetic products is disclosed. The mixing element has a hub (30) for rotationally and axially fixed coupling with a drive shaft (20) of a stirring device, an annular stirring element carrier (60) arranged concentrically around the hub (30), and at least one spoke element (40) for firmly connecting the stirring element carrier (60) to the hub. Furthermore, it is provided that at least two stirring teeth (80) are provided on the outer circumferential side of the stirring element carrier (60), and that the mean length of at least one stirring tooth (80), viewed in the plane of the stirring element carrier (60) spanned by its annular shape, is at most equal to the distance between two consecutive stirring teeth (80) in one of the circumferential directions (R1, R2) of the stirring element carrier (60).