Homogenizing Valve Flow Inversion for Shear Rate
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Solution Overview
Problem
Existing homogenization and micronization processes are inefficient due to excessive energy waste, with much energy being converted into heat rather than effectively breaking down particles, and they often require auxiliary equipment or lack adjustable components for optimal performance.
Innovation Solution
A stand-alone homogenization-micronization apparatus with a unique flow inversion design, featuring two stages of deflector plugs and a cooperating element that converts pressure into velocity, creating a high shear rate and back pressure to enhance particle breakdown efficiency without auxiliary equipment, and allowing for adjustable treatment intensity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high-pressure homogenization is used to break down particles, then particle size is reduced and homogenization is achieved, but excessive energy is wasted and converted into heat rather than effectively breaking down particles
Solution Approach 1:
The patent inverts the conventional flow direction through the valve. Instead of fluid flowing from the inlet through the passage head to the outlet, the fluid flows in reverse through the impact head and passage head. This inversion changes the flow dynamics and shear rate distribution, allowing for more efficient particle breakdown with reduced energy waste converted to heat.
Solution Approach 2:
The patent employs movable components including a movable impact head and adjustable deflector plugs that can change position dynamically. The deflector plugs can be adjusted to control flow distribution and create variable shear rates. This dynamic capability allows optimization of the homogenization process for different operating conditions, improving energy efficiency while maintaining particle size reduction.
2Manufacturing precision
If conventional homogenization apparatus is used, then particle breakdown occurs, but auxiliary equipment or additional units are required to achieve optimal performance
Solution Approach 1:
The patent combines multiple functions into a single integrated valve body. The deflector plugs, passage head, and impact head are all integrated within one valve assembly, eliminating the need for separate auxiliary equipment. The valve performs both flow control and homogenization functions simultaneously, reducing device complexity while maintaining homogenization quality.
Solution Approach 2:
The valve design provides multi-functionality through adjustable deflector plugs that can control both flow rate and shear rate distribution. The same valve structure serves as both a flow control device and a homogenization device, eliminating the need for separate auxiliary units and making the apparatus adaptable to different operating requirements.
3Adaptability or versatility
If fixed geometry homogenization valve is used, then结构简单性 is maintained, but adjustability for optimal performance is limited
Solution Approach 1:
The patent incorporates movable deflector plugs that can be adjusted to change the flow path and shear rate distribution within the valve. This dynamic adjustability allows optimization for different operating conditions without requiring multiple fixed-geometry valves. The movable components are integrated into the valve body, maintaining structural simplicity while providing adaptability.
Solution Approach 2:
The deflector plugs can be adjusted to change key flow parameters such as shear rate and flow distribution. By modifying the position of the deflector plugs, the valve can adapt to different operating requirements and product characteristics, providing versatility without significantly increasing structural complexity.
4Duration of action of stationary object
If impact ring is used to protect chamber from wear, then component lifespan is extended, but energy waste increases and homogenization efficiency decreases
Solution Approach 1:
By inverting the flow direction, the patent changes which components the fluid contacts. The reversed flow pattern reduces direct high-velocity impact on the chamber walls that would otherwise require protective impact rings. This eliminates the need for additional protective components while maintaining chamber lifespan through the redesigned flow path.
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 approach significantly reduces energy waste, increases the homogenization efficiency by maximizing shear rate and impact energy, and extends the lifespan of valve components by minimizing wear, while eliminating the need for an impact ring and optimizing energy use for particle breakdown.
Implementation Method 1
The fluid under high pressure in the first chamber presses on a surface of the impact head, exerting a pressure on it that tends to widen the passage
Implementation Method 2
A pusher is applied to the impact head and it exerts a force on the impact head in an axial direction, so as to oppose the pressure of the fluid
Implementation Method 3
as it flows through said forced passage from the first to the second chamber, the fluid undergoes a drop in pressure
Implementation Method 4
while at the same time it is also accelerated according to the equation of energy conservation. This acceleration leads to a breaking down of the particles of the fluid
Implementation Method 5
the fluid strikes against the impact ring at high velocity and this constitutes a further contribution to the breaking up of the particles. The impact ring also protects the chamber in which the impact takes place from wear
Data Source
AI summary
A homogenizing apparatus (1) comprising: —an inlet (2) for receiving a pressurized fluid, possibly also containing solid particles; —a zone wherein homogenization of the fluid takes place; —an outlet (10) for the fluid at a lower pressure with respect to the inlet pressure, wherein, in the homogenization zone, the fluid passes from a zone having a larger diameter (or volume) to a zone having a smaller diameter (or volume), the homogenization zone comprising an interacting element (9) shared by a first stage (equipped with a first deflector plug (6)) and a second stage suitable for creating back pressure (equipped with a second deflector plug (12)), where the deflector plugs (6 and 12) operate with the interacting element (9) they share, generating an increase in the shear rate within the first stage. The invention also concerns a homogenization process.