Filler Mixing Apparatus with Pre-Injection Hardener Path
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Solution Overview
Problem
Existing devices for mixing binder and hardener components to produce a ready-to-use filler often result in incorrect mixing ratios, leading to insufficient curing or unwanted enrichment of the binder component, due to air bubbles trapped in the hardener component during transport to the mixing chamber, which can cause quality issues in the final product.
Innovation Solution
The device design includes a pre-injection of a small amount of hardener component using micro-air bubbles, with the outlet opening for the hardener component positioned close to the mixing chamber inlet, and a supply channel with a larger diameter to ensure the hardener component reaches the mixing chamber quickly, along with a non-return valve to prevent backflow, ensuring a uniform mixing ratio and preventing air bubbles from entering the mixing chamber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the hardener component is transported through a long path to the mixing chamber, then the device structure is more stable, but air bubbles are trapped in the hardener component causing incorrect mixing ratios
Solution Approach 1:
The system performs a pre-injection of hardener component before the main injection. This preliminary action ensures that the mixing chamber is initially filled with hardener, establishing a bubble-free foundation before the binder component is added, thereby preventing air bubbles from affecting the final mixing ratio
Solution Approach 2:
The system separates the injection process into two distinct phases: pre-injection of hardener component and main injection of binder component. By extracting and handling the hardener component separately first, the system eliminates air bubbles before they can contaminate the final mixture
2Manufacturing precision
If the outlet opening for hardener component is positioned far from the mixing chamber inlet, then the supply channel can be larger in diameter, but the hardener component takes longer to reach the mixing chamber causing mixing ratio variations
Solution Approach 1:
The system advances the hardener component to the mixing chamber inlet before the binder component is injected. This preliminary positioning ensures that when mixing begins, both components are already at the correct location, eliminating transport time variations and ensuring precise mixing ratios
Solution Approach 2:
The pre-injection phase ensures continuous availability of hardener component at the mixing chamber inlet. This continuous positioning eliminates interruptions and time delays in the mixing process, maintaining consistent mixing ratios throughout operation
3Manufacturing precision
If a pre-injection of hardener component is performed, then the mixing ratio is improved, but the device complexity increases due to additional control mechanisms
Solution Approach 1:
The system uses the expansion of micro-air bubbles within the hardener component itself to drive the pre-injection process. This self-service mechanism eliminates the need for separate actuators or complex control systems for the pre-injection phase, achieving precise mixing ratios through the material's own properties
Solution Approach 2:
Micro-air bubbles trapped in the hardener component serve as an intermediary mechanism to drive the pre-injection. These bubbles expand and push the hardener forward, acting as a natural mediator that simplifies the control system while maintaining precise mixing ratios
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 ensures a consistent 2% hardener to 98% binder ratio, achieving proper curing and preventing air pockets, resulting in a high-quality, fully hardenable filler compound with improved processing times and reduced irregularities in the final product.
Implementation Method 1
a small amount of hardener component B is injected by expansion of the micro-air bubbles as a pre-injection compared to the feed of the binder component A
Implementation Method 2
The components are mixed with one another as a result of the friction that occurs and the adhesion of the components to the inner wall of the hose
Implementation Method 3
The components are mixed with one another as a result of the friction that occurs and the adhesion of the components to the inner wall of the hose
Implementation Method 4
a non-return valve to prevent backflow
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The apparatus for mixing a binder component (A) with a curing component (B) to give a pasty mixed material for preparing a ready-to-use filler for filling surfaces of vehicle bodies comprises an apparatus plate (30) which is arranged in an apparatus component (20) and is for receiving the containers (40, 50) for the two components (A, B), wherein the apparatus plate (30) comprises inlet openings (31, 32) and outlet openings (33, 34) and also the feed channels (35, 36) connecting the inlet openings and the outlet openings, and also a mixing device (60), and wherein the feed channel (36) for the curing component (B) is constructed in such a manner and the mixing device (60) is fastened to the apparatus plate (30) in such a manner that a shortening of the path of the curing component (B) up to the binder component (A) in the mixing device (60) for achieving a uniform time for the gelling of the two components (A, B) of 2 to 3 minutes is achieved.