Dispersion Mixing Device with Dynamic Separating Gap
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Solution Overview
Problem
Conventional mixing and dispersing devices in the paint industry often fail to efficiently reduce oversize material, leading to suboptimal particle size distribution and throughput in the production of paints and lacquers.
Innovation Solution
A device with a dynamic separating gap and recirculation system, where dispersion grinding aids are used in the first process region to break down agglomerates, and a dynamic separating gap prevents larger particles from passing into the second process region, allowing for high throughput and cost-effective operation without grinding aids in the pump chamber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional mixing process with rotor and housing is used, then the average pigment size is dispersed into the necessary range, but oversize material remains and throughput is limited
Solution Approach 1:
The mixing process is divided into two distinct process regions: a first process region for initial mixing and dispersion, and a second process region for further processing. This segmentation allows each region to be optimized for its specific function, enabling both good particle size distribution and high throughput simultaneously
Solution Approach 2:
A dynamic separating gap is introduced between the two process regions, which can be adjusted in size. This dynamic element allows the system to adapt to different material properties and throughput requirements while maintaining effective separation of oversize material, thus resolving the contradiction between precision and productivity
2Manufacturing precision
If a separating device with very small dynamic gap is used to reduce oversize material, then particle size distribution improves, but output is reduced
Solution Approach 1:
The separating function is segmented from the main mixing process by creating a distinct interface between the first and second process regions. This allows the separating gap to be optimized for particle size control while the overall system maintains high throughput through the two-stage configuration
Solution Approach 2:
The dynamic separating gap between the two process regions can be adjusted to optimize the balance between oversize material reduction and output. By making the gap adjustable rather than fixed, the system can adapt to different production requirements while maintaining both precision and productivity
3Manufacturing precision
If grinding aids are used in the pump chamber to disperse materials, then dispersion quality improves, but the risk of blockages increases and operation becomes more complex
Solution Approach 1:
The pump chamber is separated from the first process region, and grinding aids are removed from the pump chamber. This extraction eliminates the source of blockages while maintaining dispersion quality through the dedicated first process region where grinding aids can be used without risking pump blockages
Solution Approach 2:
A dynamic separating gap acts as an intermediary between the first process region (where grinding aids are used) and the pump chamber (where grinding aids are absent). This intermediary allows the system to enjoy the benefits of grinding aids for dispersion while protecting the pump from blockages
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 achieves efficient reduction of oversize material and high throughput by using dispersion grinding aids and a dynamic separating gap, enabling optimal dispersion and preparation for further fine grinding stages, while minimizing the risk of blockages and maintaining cost efficiency.
Implementation Method 1
A dynamic separating gap, which... achieves separation of the dispersion grinding aids before the mixture is conducted into the second process region
Implementation Method 2
Grinding tools which are set in rotation by a drive shaft are arranged on a rotor in the first process region
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A device (1) for mixing, in particular dispersing, includes a housing (2) with at least one inlet (3) and a grinding chamber (13). In addition, the grinding chamber (13) includes a first process region (4) for mixing fed materials, wherein the materials are introducible into the first process region (4) through the at least one inlet (3), and a second process region (5) for diverting the mixture to an outlet (6) as well as a separating device (7) for separating the first process region from the second process region, and a rotor (8) for mixing, in particular dispersing the mixture in the first process region (4), wherein the rotor is drivable by a drive shaft (9). A pump (10) connected upstream is drivable by the drive shaft (9) and materials are feedable by means of the pump (10) into the first process region (4) and the first process region comprises a dispersion volume within the range of 11–501, in a preferred manner of 41–12 and particularly preferred is 61.