Compact Static Mixer Using Shear and Impingement
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Solution Overview
Problem
Existing static mixers are inefficient in terms of size, pressure drop, and dead volume, which affects fluid mixing in industries like semiconductors, leading to increased waste and latency in recipe changes.
Innovation Solution
A compact static mixing device utilizing fluid shear, turbulence, and impingement technologies within a fluid mixing chamber, featuring multiple stream dividers and plenums to efficiently mix fluids, minimizing pressure drop and dead volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional static mixers use rigid baffles or spiral inserts to divide and recombine flow streams, then mixing is achieved, but the device size, dead volume, and pressure drop increase
Solution Approach 1:
The mixing chamber is segmented into multiple zones with sequential stream dividers that progressively subdivide the flow. Each stream divider creates multiple sub-streams that are redirected and recombined, achieving thorough mixing through staged segmentation rather than a single complex structure.
Solution Approach 2:
The patent transitions from traditional two-dimensional planar baffles to three-dimensional curved stream dividers that extend into the flow path. These 3D structures create spiral and impingement flow patterns that enhance mixing efficiency while reducing the overall device length and dead volume compared to conventional 2D baffle designs.
2Quantity of substance
If traditional static mixers use multiple subdivisions and recombinations of flow streams, then mixing is achieved, but pressure drop increases
Solution Approach 1:
The stream dividers are designed with curved surfaces that dynamically redirect flow in spiral and impingement patterns. This dynamic flow manipulation creates efficient mixing through fluid inertia and turbulence rather than relying on multiple sharp 90-degree bends, thereby reducing pressure drop while maintaining mixing effectiveness.
Solution Approach 2:
The patent replaces the conventional mechanical baffle system with a streamlined curved surface system that uses fluid dynamics (spiral flow and impingement) to achieve mixing. This substitution eliminates the need for multiple rigid redirection elements that cause high pressure losses, reducing overall pressure drop while maintaining compact size.
3Quantity of substance
If traditional static mixers are designed to mix fluids effectively, then mixing performance is achieved, but device size increases
Solution Approach 1:
Multiple stream dividers and flow subdivision stages are nested within a single compact mixing chamber. Each stream divider is positioned sequentially along the flow path, with subsequent dividers processing the already-subdivided streams. This nested arrangement achieves multiple mixing stages within a minimized chamber length, reducing overall device size while maintaining effective mixing.
4Loss of substance
If traditional static mixers reduce dead volume, then waste during flushing is reduced, but mixing effectiveness may be compromised
Solution Approach 1:
The patent optimizes the geometric parameters of the stream dividers, including curvature radius, subdivision angle, and impingement zone dimensions, to achieve effective mixing within a minimized dead volume. By carefully tuning these parameters, the design maintains thorough mixing performance while reducing the flushing volume required, thereby minimizing waste and latency.
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 device effectively reduces pressure drop and dead volume, enhancing fluid mixing efficiency and reducing waste and latency in fluid systems.
Implementation Method 1
a first stream divider in the fluid mixing chamber downstream of the inlet having plural first channels for dividing (shear) flow from main flow inlet into multiple first streams
Implementation Method 2
a second stream divider in the fluid mixing chamber downstream of the first peripheral plenum having plural second channels for dividing the recombined flow into multiple second streams that are separately directed inwardly toward one another along respective spiral paths to a first inner plenum for recombining of the multiple second streams (turbulence)
Implementation Method 3
a fourth stream divider in the fluid mixing chamber downstream of the second peripheral plenum having plural fourth channels for dividing the recombined flow in multiple fourth streams that are separately directed inwardly toward one another (impingement) along respective paths that have respective fourth stream outlets opening to a second inner plenum and oriented relative to one another such that opposing fourth flow steams impinge directly into each other
Data Source
AI summary
A static mixing device that uniquely utilizes fluid shear, turbulence and impingement in a compact package to mix fluids, in particular liquids, entering the inlet of the device. The static mixing device enables a reduction in dead volume and/or pressure drop when compared to prior art static mixers.