Eccentric Triangular Impeller Kneader Self-Cleaning
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Solution Overview
Problem
Existing kneader/stirrers face issues with resin adherence to impellers and the processing chamber, leading to operational troubles due to solidified resin becoming wedged between parts, which affects self-cleaning and prolonged operation.
Innovation Solution
A kneader/stirrer design featuring regular triangular impellers on parallel rotary shafts, offset and eccentrically pivoted to ensure effective scraping and removal of resin from both impeller surfaces and the chamber walls, promoting self-cleaning and balanced operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If disk-shaped impellers are used in the kneader/stirrer, then the structure is simple and easy to manufacture, but resin adheres strongly to the impellers and chamber walls, causing solidified resin to wedge between parts
Solution Approach 1:
The patent applies asymmetry by changing the impeller shape from a symmetric disk to an asymmetric configuration with a pressing portion and a scraping portion. The pressing portion has a curved surface that contacts the chamber wall, while the scraping portion extends axially to scrape resin from the wall. This asymmetric design enables the impeller to both press material for mixing and scrape adhered resin, preventing wedging while maintaining manufacturing feasibility.
2Reliability
If impellers are arranged to be in close proximity for self-cleaning, then resin removal capability is improved, but the risk of resin wedging between impellers increases
Solution Approach 1:
The patent segments the impeller function into distinct pressing and scraping portions. The pressing portion handles material compression and mixing, while the scraping portion specifically addresses resin removal from chamber walls. This functional segmentation allows the impeller to perform self-cleaning through the scraping action without requiring impellers to be in close proximity, thereby preventing resin wedging between components.
3Productivity
If multiple impellers are positioned at the same axial location for enhanced mixing, then kneading efficiency is improved, but resin accumulation between adjacent impellers occurs
Solution Approach 1:
The patent applies asymmetry by designing impellers with distinct pressing and scraping portions that perform different functions. The scraping portion specifically addresses resin removal from chamber walls, preventing accumulation between adjacent impellers. This asymmetric design maintains high kneading efficiency through the pressing action while the scraping action continuously removes adhered resin, preventing loss of material through accumulation.
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 design enhances self-cleaning ability, preventing resin wedging and allowing stable, long-term operation by ensuring reliable removal of adhered materials, thus improving polymerization reactions and processing efficiency.
Implementation Method 1
the pair of first and second impellers are configured to be eccentrically pivoted with one of the three apexes of one of the pair of first and second impellers kept in contact with or close proximity to the contour of the other of the pair of first and second impellers, whereby material to be processed that is adhered to the outer periphery of either of the pair of first and second impellers can be removed by the other of the pair of first and second impellers
Data Source
AI summary
A kneader/stirrer includes two rotary shafts extending parallel to each other in the processing chamber, and first and second regular triangular impellers mounted to the respective rotary shafts. The first impellers are located at the same axial positions as the respective first impellers. The impellers are fixed to the respective rotary shafts at points offset from the centers of the respective impellers in a predetermined direction by a predetermined distance such that when the two rotary shafts rotate in the same direction at the same speed, each pair of first and second impellers are eccentrically pivoted, with one apex of one of the pair of impellers kept in contact with or in close proximity to the contour of the other impeller, thereby scraping off polycondensation resin (material to be processed) adhered to the other impeller.