High-Viscosity Stirring Device With Independent Circulation and Shear
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Solution Overview
Problem
Existing stirring devices are inadequate for high-viscosity fluids, leading to cavitation, insufficient refinement, and instability of emulsified liquids, requiring additional heating and longer processing times, and increased cleaning efforts.
Innovation Solution
A stirring device with a circulating impeller and dispersion blade, guided by a ring, applies concentric rotation to create a downward flow and shear force, enhancing emulsification efficiency for viscosities between 10,000 and 100,000 mPa·s.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a rotor-stator type device is used to apply shear force to refine the oil phase, then the emulsification efficiency is improved, but when the viscosity exceeds 1,000 mPa·s, cavitation occurs and the device cannot continuously supply the stirring object, causing it to idle
Solution Approach 1:
The stirring device is segmented into two independent functional components: a ribbon impeller for bulk circulation and a dispersion blade for localized high-shear emulsification. This segmentation allows each component to operate within its optimal viscosity range, enabling continuous operation with high-viscosity materials without cavitation.
Solution Approach 2:
The ribbon impeller acts as an intermediary that pre-circulates and conditions the high-viscosity stirring object before it reaches the dispersion blade. This intermediary action reduces the viscosity and prepares the material, allowing the dispersion blade to function effectively without experiencing cavitation or idling.
2Productivity
If the viscosity of the stirring object is lowered by raising the operation temperature to perform emulsification, then the stirring efficiency is improved, but a large amount of power and longer processing time are required for heating and cooling
Solution Approach 1:
The invention replaces the thermal field (heating/cooling system) with a mechanically optimized stirring system. By designing the ribbon impeller and dispersion blade with specific geometries and rotation speeds, the device achieves effective emulsification of high-viscosity materials through mechanical action alone, eliminating the need for temperature control.
3Productivity
If the viscosity of the stirring object is lowered by raising the operation temperature, then the emulsification operation can be performed, but a long time is required for cleaning work after the operation
Solution Approach 1:
By replacing thermal processing with mechanically optimized stirring, the invention maintains the stirring object at room temperature throughout the process. This eliminates the temperature changes that would require extended cleaning time, allowing for quick and easy cleaning after operation.
4Manufacturing precision
If a dispersion blade rotates at high speed to apply shear force, then the refinement of the stirring object is improved, but when the viscosity is 10,000 mPa·s or higher, the stirring object is not continuously supplied, causing the device to idle
Solution Approach 1:
The device segments the stirring function into bulk circulation (ribbon impeller) and localized refinement (dispersion blade). The ribbon impeller ensures continuous supply by circulating the high-viscosity material, while the dispersion blade focuses on refinement, allowing both functions to operate effectively without idle time.
Solution Approach 2:
The ribbon impeller maintains continuous circulation and supply of the stirring object to the dispersion blade through coordinated rotation. This continuous action ensures that the dispersion blade always has material to process, eliminating idle time even with high-viscosity materials.
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 ensures stable emulsification without heating, reduces power consumption, and minimizes cleaning time by effectively refining high-viscosity fluids.
Implementation Method 1
The circulating impeller is disposed along the inner peripheral wall of the stirring tank, and rotates around the vertical axis to form at least a downward flow in a stirring object existing inside the stirring tank
Implementation Method 2
The dispersion blade rotates to apply a shear force to the stirring object
Data Source
Figure 1
Figure 2~3
Figure 4A~4B
AI summary
A stirring device includes a circulating impeller 3 and a dispersion blade 4 which are rotatable independently of each other, and a guide ring 5 fixed near a radially outer side of the dispersion blade 4. The circulating impeller 3 is disposed along an inner peripheral wall 2a of a stirring tank 2, and rotates around a vertical axis to form a flow at least a downward flow in a stirring object existing inside the stirring tank 2. The dispersion blade 4 rotates to apply a shear force to the stirring object, and is disposed at a radially inner position of the stirring tank 2 from the circulating impeller 3, and at a position in contact with a flow of the stirring object, which is formed by the circulating impeller 3. The guide ring 5 has an inner peripheral surface facing an outer peripheral edge of the dispersion blade 4.