Dynamic Rotor Mixing for Viscous Fluid Temperature Control
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Solution Overview
Problem
Existing mixing devices for viscous fluids, such as melted polymers, suffer from non-uniform temperature control leading to degradation and require large installations with high pressure loss, resulting in additional heating and costs.
Innovation Solution
A dynamic mixing device with a stator and rotor within a mixing chamber, utilizing temperature control channels to manage fluid temperature and promote mixing through shear forces and fluid flow, ensuring effective temperature control and uniform mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If external temperature control system is used, then temperature control is achieved, but temperature gradient within fluid increases and manufacturing precision deteriorates
Solution Approach 1:
The mixing chamber is divided into multiple temperature control zones with independent temperature control channels. This segmentation allows different regions of the fluid to be controlled at different temperatures, eliminating the temperature gradient problem while maintaining overall temperature control.
Solution Approach 2:
Temperature control channels are introduced as intermediary structures within the mixing chamber. These channels serve as mediators between the external temperature control system and the fluid, enabling direct thermal interaction and uniform temperature distribution without creating temperature gradients.
2Productivity
If large static mixer is used to achieve desired mixing effect, then mixing effectiveness is improved, but installation space requirement and pressure loss increase
Solution Approach 1:
The mixing device transitions from static to dynamic operation with a rotating rotor that creates vortex flow. This dynamic mixing mechanism achieves effective mixing in a compact space without requiring large installation footprint, while the vortex flow pattern reduces pressure loss compared to traditional static mixers.
Solution Approach 2:
The mixing mechanism utilizes three-dimensional vortex flow created by the rotating rotor instead of linear or planar mixing paths. This dimensional transformation allows efficient mixing within a compact chamber, reducing both installation space requirements and pressure loss while maintaining mixing effectiveness.
3Temperature
If static mixer with heat exchange tubes is used, then heat exchange is achieved, but mixing effect is poor and device complexity increases
Solution Approach 1:
The temperature control channels are integrated directly into the mixing chamber structure, merging the heat exchange function with the mixing function. This integration eliminates the need for separate heat exchange tubes and components, reducing device complexity while achieving effective heat exchange during the mixing process.
Solution Approach 2:
The mixing chamber structure serves multiple functions simultaneously: it acts as the mixing vessel, contains the temperature control channels for heat exchange, and houses the rotating rotor for dynamic mixing. This multi-functionality reduces the number of separate components and simplifies the overall device structure.
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
Achieves simultaneous and efficient mixing and temperature control of viscous fluids, reducing degradation risks and installation size while minimizing pressure loss.
Implementation Method 1
promote mixing through shear forces and fluid flow
Implementation Method 2
promote mixing through shear forces and fluid flow
Implementation Method 3
utilizing temperature control channels to manage fluid temperature
Data Source
AI summary
An extruder includes a mixing device having a mixing chamber formed by a housing, a stator and a rotor. The stator and the rotor are arranged at least partially within the mixing chamber. The stator is connected to the housing and/or is formed by the housing. The rotor is rotatable about an axis of rotation (D). At least one free space, into which the stator projects at least partially in the direction of the axis of rotation (D), is formed by the rotor. The stator and/or the rotor have/has at least one temperature control channel, through which a temperature control fluid can be made to flow in order to control the temperature of the stator and/or of the rotor. The extruder further includes a screw housing, a screw drive, and an extruder screw, which is mounted to the screw housing and is coupled to the screw drive.