Continuous Dry Mortar Mixing with Ring Inlet and Segmented Chamber
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Solution Overview
Problem
Existing mixing devices for dry mortar and concrete struggle with incomplete and uneven mixing, leading to defects in plaster layers and screeds due to insufficient water distribution and mixing efficiency, resulting in qualitative variations and increased effort for producing consistent mortar mixtures.
Innovation Solution
A mixing device with a ring-shaped water inlet and eccentric screw pump design ensures even water distribution within the mixing chamber, minimizing wear on the mixing shaft and allowing for continuous, intensive mixing of dry mortar with a metered amount of water, featuring an axially divisible mixing chamber for flexible operation and easy cleaning, and enhanced mixing tools for improved premixing and discharge efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional mixing device is used to mix dry mortar with water, then the mixing process is simple, but the mixing is incomplete and uneven, leading to defects in plaster layers
Solution Approach 1:
The mixing chamber is divided into multiple zones: a pre-mixing zone with radial mixing blades that break up mortar clumps, and a main mixing zone with axial mixing blades. This segmentation allows different mixing actions to occur in different regions, ensuring complete and uniform mixing of the mortar mixture.
Solution Approach 2:
A pre-mixing section is provided before the main mixing chamber where dry mortar is initially mixed with water using radial mixing blades. This preliminary mixing action prepares the mortar by breaking up clumps and distributing water evenly, so that the main mixing chamber only needs to complete the mixing process, ensuring uniform final product.
2Manufacturing precision
If water is supplied without precise quantity control, then the mixing process is simple, but qualitatively different compounds are produced requiring rework
Solution Approach 1:
A metering pump is used to supply water to the mixing chamber, providing precise quantity control of the water added to the mortar. This feedback-controlled water supply ensures consistent water-to-mortar ratios, producing uniform mortar quality and eliminating the need for rework due to quality variations.
3Productivity
If the mixing container is not large enough, then the device is compact, but only comparatively small quantities of mortar compound can be produced
Solution Approach 1:
The mixing device is designed for continuous operation with continuous supply of dry mortar and water, and continuous discharge of mixed mortar. This continuous mixing process allows small mixing chambers to produce large quantities of mortar over time, achieving high productivity without requiring large container volumes.
4Manufacturing precision
If intensive mixing is applied to difficult-to-mix mortar, then mixing quality improves, but energy consumption increases
Solution Approach 1:
The mixing process is divided into two stages with different mixing intensities: a pre-mixing stage with radial blades that uses moderate energy to break up clumps and distribute water, and a main mixing stage with axial blades that uses higher energy to complete the mixing. This segmented approach achieves complete mixing while minimizing total energy consumption by applying intensive mixing only where necessary.
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
This solution enables high-quality, continuous mixing of difficult-to-mix mortars, reducing adhesion defects and increasing productivity by ensuring thorough mixing and optimal discharge, while minimizing energy consumption and extending equipment lifespan.
Implementation Method 1
a first eccentric screw pump (90) is connected to the discharge side of the mixing chamber (2)
Implementation Method 2
a mixer shaft (8) with mixing tools (15 to 18) that can be rotated about an axis of rotation (8.1) by means of a drive (7) is inserted inside the mixing chamber (2)
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
Device for mixing dry mortar with water comprises a mixing container (1) and a cylindrical mixing chamber with flanges (3, 5) having a concentric inlet opening (4) on one side and a concentric outlet opening (6) having a concentric recess (6.1) on the other side. Axial distribution openings (3.2) are arranged in the region of the inner side of the flange (3).