Emulsification Device Laminar Flow Mixing Chamber
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Solution Overview
Problem
Existing emulsifying devices for continuous production of emulsions and dispersions often fail to produce nanoemulsions and liquid-crystalline structures efficiently, as they either allow cavitation forces or are not designed to prevent turbulence, leading to suboptimal mixing and energy consumption.
Innovation Solution
An emulsifying device with a rotationally symmetric, airtight mixing chamber featuring a stirrer unit that ensures laminar flow, with specific ratios of inlet to outlet line distance and stirrer arm length, and a magnetic coupling system to minimize energy consumption and prevent air inclusion, allowing for the continuous production of emulsions and dispersions with a liquid-crystalline structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional continuous emulsifying devices are used, then continuous production is achieved, but cavitation forces and turbulence occur leading to suboptimal mixing and high energy consumption
Solution Approach 1:
The invention changes the flow regime parameter from turbulent to laminar flow by designing a specific mixing chamber geometry with controlled dimensions and a centrally positioned stirrer. This parameter change eliminates cavitation forces while maintaining continuous production capability, thereby reducing energy consumption without sacrificing productivity.
Solution Approach 2:
The invention replaces the conventional high-shear mechanical mixing system that generates cavitation with a laminar flow-based mixing system. By substituting the mechanical turbulence-generating approach with a controlled laminar flow approach using specific chamber geometry and stirrer design, energy losses from cavitation are eliminated while continuous production is maintained.
2Productivity
If conventional mixing chambers are used, then continuous production is achieved, but air inclusion occurs and mixing precision is insufficient for nanoemulsion production
Solution Approach 1:
The invention changes the flow regime parameter from turbulent to laminar flow by designing a specific mixing chamber geometry with controlled dimensions and a centrally positioned stirrer. This parameter change eliminates cavitation forces while maintaining continuous production capability, thereby reducing energy consumption without sacrificing productivity.
Solution Approach 2:
The invention positions the stirrer centrally within the mixing chamber, creating a symmetric flow pattern that prevents air inclusion. The asymmetric positioning of inlet and outlet lines relative to the chamber geometry further optimizes flow patterns to eliminate dead zones and prevent air entrapment, thereby improving mixing precision for nanoemulsion production.
3Stability of the object's composition
If high-shear mixing is used to achieve thorough mixing, then mixing efficiency improves, but energy consumption increases and liquid-crystalline structures cannot form
Solution Approach 1:
The invention changes the flow regime parameter from turbulent to laminar flow by designing a specific mixing chamber geometry with controlled dimensions and a centrally positioned stirrer. This parameter change eliminates cavitation forces while maintaining continuous production capability, thereby reducing energy consumption without sacrificing productivity.
Solution Approach 2:
The invention maintains continuous laminar flow through the mixing chamber, ensuring thorough mixing without intermittent high-shear pulses. The continuous laminar flow regime allows sufficient residence time for liquid-crystalline phase formation while maintaining mixing effectiveness, thereby reducing energy consumption compared to intermittent high-shear mixing.
4Stability of the object's composition
If conventional stirrer designs are used, then mixing is achieved, but turbulence and cavitation forces prevent liquid-crystalline phase formation
Solution Approach 1:
The invention changes the flow regime parameter from turbulent to laminar flow by designing a specific mixing chamber geometry with controlled dimensions and a centrally positioned stirrer. This parameter change eliminates cavitation forces while maintaining continuous production capability, thereby reducing energy consumption without sacrificing productivity.
Solution Approach 2:
The invention divides the mixing chamber into distinct flow zones: a central mixing zone with laminar flow for thorough mixing, and peripheral zones that allow controlled flow transition. This segmentation enables effective mixing without generating harmful turbulence and cavitation forces, while providing the stable conditions necessary for liquid-crystalline phase formation.
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, energy-efficient production of emulsions and dispersions with a liquid-crystalline structure, minimizing energy consumption and maintaining a laminar flow to ensure thorough mixing and effective droplet breakup, resulting in a compact and cost-effective process.
Implementation Method 1
the components are mixed turbulently by the shear forces exerted by the stirrer units
Implementation Method 2
the percolating mixing area in which the components are mixed further and the turbulent flow decreases
Implementation Method 3
the viscosity increases, caused either by constant comminution of the droplets or by formation of liquid-crystalline phases
Implementation Method 4
in which a lyotropic, liquid-crystalline phase is established in the mixture of the components
Implementation Method 5
Controlled and energy-efficient severing of the drops during the mixing process or the formation of liquid-crystalline phases then occurs in the laminar mixing area under conditions of elongational flow
Data Source
AI summary
The invention relates to an emulsification device for continuously producing emulsions, nano-emulsions, and/or dispersions having a liquid crystalline structure, comprising a) at least one mixing system, b) at least one drive for the stirring element, and c) at least one delivery unit for each component or each component mixture.