Helical Scraper Mixer for Continuous Shear and Compression Mixing
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Solution Overview
Problem
Existing mixers face inefficiencies in the mixing process, particularly in continuously processing materials without sufficient application of compressive, shearing, and spatulating forces.
Innovation Solution
A mixer design featuring helically recessed rotary bodies with inclined scrapers that apply compressive, shearing, and spatulating forces to materials as they are conveyed from a supply port to a discharge port, utilizing opposing rotary shafts with synchronized or differential rotation to enhance mixing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a batch mixing process is used with a muller wheel, then mixing actions (kneading, smearing, spatulating) are applied to the material, but the mixing process efficiency is low due to discontinuous operation
Solution Approach 1:
The patent inverts the conventional batch mixing approach by implementing continuous mixing where the rotary body with helical recesses and scrapers continuously conveys material through the mixing zone. Material enters at one end and is continuously processed and discharged at the other end, eliminating the start-stop nature of batch mixing and significantly improving productivity.
Solution Approach 2:
The rotary body with helical recesses and scrapers creates a continuous mixing action where material is constantly being conveyed, mixed, and discharged. The continuous rotation ensures that the mixing process never stops, maintaining continuous useful action and improving overall mixing efficiency compared to intermittent batch processing.
2Manufacturing precision
If multiple forces (compressive, shearing, spatulating) are applied to material, then mixing quality improves, but the device complexity increases
Solution Approach 1:
The patent merges multiple mixing functions into a single integrated rotary body. The helical recesses and scrapers work together as one unified component to simultaneously apply compressive, shearing, and spatulating forces to the material, achieving high mixing quality without requiring multiple separate mixing mechanisms.
Solution Approach 2:
The rotary body with helical recesses and scrapers serves multiple functions simultaneously: it conveys material forward, applies compressive force through the helical action, creates shearing force between layers, and provides spatulating action at the discharge end. This multi-functionality in a single component achieves comprehensive mixing quality without proportionally increasing device complexity.
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 enables continuous, efficient mixing with improved application of multiple forces, reducing maintenance complexity and ensuring thorough mixing of materials, including powders, while maintaining a negative pressure state for enhanced mixing outcomes.
Implementation Method 1
a first recessed portion recessed in a helical shape, the helical shape advancing in a direction in which the material is conveyed by the first rotary body as the helical shape turns in a rotation direction of the first rotary shaft
Implementation Method 2
Each of the plurality of first scrapers has a first inclined surface inclined so as to press the material toward the discharge port by rotation of the first rotary shaft
Data Source
AI summary
A mixer includes: a first rotary shaft provided in a housing across a first end and a second end of the housing in one direction; and a first rotary body mounted on the first rotary shaft inside the housing, the first rotary body that conveys a material supplied from a supply port toward a discharge port while mixing the material as the first rotary shaft rotates. The first rotary body includes: a first main body including a first recessed portion recessed in a helical shape; and a plurality of first scrapers provided in the first recessed portion and arranged along the first recessed portion. Each first scraper has a first inclined surface inclined so as to press the material toward the discharge port by rotation of the first rotary shaft.