Continuous Paste Mixer With Stacked High-Shear Assemblies
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Solution Overview
Problem
Conventional tub paddle mixers struggle with insufficient shear for non-Newtonian thixotropic materials like lead-acid battery paste, leading to uneven mixing, longer mixing times, and potential operational inefficiencies due to inconsistent viscosity and exothermic reactions.
Innovation Solution
A continuous paste mixer with high-shear mixing apparatus and a controller configured to automatically control movement and operation of the mixer according to one or more mixing profiles, the one or more mixing profiles, the mixer assemblies, and a controller configured to automatically control the mixing apparatus, and a controller configured to automatically control the mixing apparatus, and a controller configured to automatically control the mixing apparatus, and a controller configured to automatically control the mixing process, the mixer assemblies configured to extend and stack with respect to the frame, the mixer assemblies configured to extend and stack with respect to the frame, the mixer assemblies configured to extend and stack with respect to the frame, the mixer assemblies to mix various ingredients continuously and uniformly without risking uncontrolled exothermic reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional tub paddle mixers are used, then the structure is simple and easy to operate, but the shear force is insufficient for proper dispersion of non-Newtonian thixotropic materials
Solution Approach 1:
The mixing system is divided into multiple independent mixer assemblies (first, second, third, and fourth mixer assemblies) arranged in series. Each assembly contributes to the overall shear force applied to the paste, allowing progressive breakdown of agglomerates and uniform dispersion without requiring excessive complexity in a single unit.
Solution Approach 2:
The patent transitions from a single horizontal tub mixer to a vertical stack of multiple mixer assemblies. This dimensional change allows gravity to assist material flow through each stage while each assembly applies shear force, creating a multi-stage processing system that achieves high shear without excessive complexity.
2Loss of time
If conventional tub paddle mixers are used, then the mixing time is extended, but the equipment simplicity is maintained
Solution Approach 1:
The continuous mixer operates with paste flowing continuously through multiple mixer assemblies in series, eliminating the batch loading and unloading cycles of conventional mixers. This continuous operation significantly reduces mixing time while maintaining high productivity, as the paste is constantly subjected to shear forces without interruption.
Solution Approach 2:
The paste receives preliminary mixing action in the first mixer assembly, then progresses through subsequent assemblies for further refinement. This staged preliminary action ensures that agglomerates are broken down progressively, reducing the total time required to achieve uniform dispersion compared to single-stage mixing.
3Manufacturing precision
If conventional tub paddle mixers are used, then the equipment is simple, but the mixing uniformity of non-Newtonian fluids is poor
Solution Approach 1:
Each mixer assembly in the stack provides a localized mixing zone with specific shear conditions. The paste experiences different shear rates and mixing intensities in each assembly, allowing progressive refinement of uniformity. This distributed local quality approach achieves superior overall mixing uniformity without requiring excessive complexity in any single zone.
Solution Approach 2:
The continuous flow of paste through multiple dynamic mixing zones allows the system to adapt to the non-Newtonian thixotropic behavior of the material. As paste moves through each assembly, its viscosity changes in response to applied shear, and the continuous dynamic action ensures uniform mixing throughout the process, unlike static batch mixing.
4Adaptability or versatility
If conventional tub paddle mixers are used, then the batch size flexibility is limited, but the device structure remains simple
Solution Approach 1:
The continuous mixer design handles a wide range of paste viscosities and flow rates through its multi-stage configuration. The same basic mixer assembly structure can process different batch sizes by adjusting flow rates, making the system universally applicable to various production scales without requiring complex reconfiguration, thus achieving adaptability with moderate complexity.
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 continuous mixer effectively handles the shear stress of the mixer assemblies, the mixer assemblies, the mixer, and the mixer assemblies configured to extend and stack with respect to the frame, the mixer assemblies configured to extend and stack with the mixer, the mixer assemblies configured to mix various ingredients continuously and uniformly without risking uncontrolled exothermic reactions.
Implementation Method 1
The continuous paste mixer comprises a mixing apparatus secured to a frame. The mixing apparatus includes one or more mixer assemblies configured to extend and stack with respect to the frame, the one or more mixer assemblies to mix various ingredients (thixotropic and/or non-Newtonian) continuously and uniformly
Implementation Method 2
the one or more mixer assemblies to mix various ingredients (thixotropic and/or non-Newtonian) continuously and uniformly without risking uncontrolled exothermic reactions
Data Source
AI summary
A continuous paste mixer comprising a mixing apparatus secured to a frame is described herein. The mixing apparatus includes one or more mixer assemblies configured to extend and stack with respect to the frame, the one or more mixer assemblies to mix various ingredients (thixotropic and/or non-Newtonian) continuously and uniformly without risking uncontrolled exothermic reactions. The continuous paste mixer comprises a support member operatively connected to the mixing apparatus, and a controller configured to automatically control movement and operation of the high-shear mixer during mixing according to one or more mixing profiles.