Flow Splitting Adapter for Reactive Liquid Mixing
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Solution Overview
Problem
In industrial processes involving the mixing and delivery of reactive liquids, such as epoxy resin and curing agents, the continuous reaction during transit through static mixers can lead to premature hardening, causing mixer failure and waste when flow stops, necessitating continuous purge flows that waste materials.
Innovation Solution
A flow splitting adapter positioned between dual fluid sources and a static mixer, which splits the flow before delivery, isolating the streams and reducing the volume and number of mixing elements required, thereby minimizing the purge flow needed to maintain the mixer's viability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a static mixer is used to mix reactive liquids, then adequate mixing is achieved, but the reaction continues during transit causing premature hardening and mixer failure
Solution Approach 1:
The adapter divides the flow into multiple separate channels, keeping reactive streams isolated until the mixing zone. This segmentation prevents premature reaction while maintaining mixing effectiveness through controlled introduction of streams into the static mixer.
Solution Approach 2:
The adapter acts as an intermediary device between the dual cartridge syringe and static mixer. It introduces a flow splitting function that isolates reactive streams during transit while ensuring proper mixing at the destination, thereby protecting the static mixer from premature hardening.
2Loss of substance
If flow stops between dispensing events, then material is saved, but the reaction continues causing hardening and mixer replacement
Solution Approach 1:
The adapter preliminarily prevents the harmful reaction by isolating streams in separate flow passages before they enter the static mixer. This preliminary anti-action ensures that even when flow stops, the reactive compositions remain separated and do not harden, eliminating the need for continuous purge flows.
3Reliability
If continuous purge flow is used to prevent hardening, then mixer viability is maintained, but composition material is wasted
Solution Approach 1:
By segmenting the flow paths and isolating reactive streams in separate passages, the adapter eliminates the need for continuous purge flow. The segmentation ensures that material only mixes when actually dispensing, allowing the system to stop flow without causing hardening, thus eliminating material waste associated with purge operations.
4Stability of the object's composition
If a larger static mixer is used to ensure adequate mixing, then mixing performance is improved, but purge flow requirements increase
Solution Approach 1:
The adapter's flow splitting architecture allows for a more compact static mixer design. By pre-separating streams and controlling their introduction, the system achieves adequate mixing in a smaller mixer volume, thereby reducing the amount of material required for purge flows while maintaining mixing performance.
Data Source
AI summary
A method and an adapter for improving the efficiency of a static mixer being used to mix reactive fluids such as epoxy adhesives. This allows either a small static mixer to be employed, or a smaller purge flow during dispensing operations.