Mixing Head Rotor Protrusions for Wide-Range Formulation Mixing
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Solution Overview
Problem
Existing rotary mixers are not adaptable to the wide range of flow rate ratios required for mixing monomer and catalyst solutions in reaction injection molding, particularly when using a Ru catalyst, and cannot effectively mix formulations containing fillers.
Innovation Solution
A mixing head with a rotor having alternating first and second protrusions of different widths is used to mix preparative liquid formulations, allowing for homogeneous mixing across varying flow rate ratios, including those with fillers, and includes cooling mechanisms to maintain low temperatures and prolong pot life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional rotary mixer is used to mix monomer solution and catalyst solution, then mixing function is provided, but it cannot handle wide flow rate ratios and causes reverse flow when monomer solution amount is significantly larger
Solution Approach 1:
The rotor structure is designed with multiple protrusions that create dynamic mixing zones. The protrusions generate turbulent flow patterns that adapt to varying flow rate ratios, preventing reverse flow of the catalyst solution even when monomer solution flow rate is significantly higher. The dynamic interaction between protrusions and liquid formulations ensures reliable mixing across wide flow rate ranges.
Solution Approach 2:
Different regions of the rotor are equipped with protrusions of varying sizes and shapes tailored to specific mixing requirements. The protrusions create localized high-shear zones for effective catalyst dispersion and larger mixing zones for bulk homogenization, enabling the mixer to handle both equal and unequal flow rate ratios effectively.
2Device complexity
If a rotary mixer with zero clearance between rotor and housing is used, then compact structure is achieved, but it cannot mix liquid formulations containing fillers
Solution Approach 1:
The rotor is segmented with multiple protrusions that create discrete mixing zones throughout the mixing chamber. This segmentation allows the formulation to be progressively mixed as it passes through each zone, preventing filler aggregation and ensuring homogeneous distribution even in compact mixer geometries with minimal clearance.
Solution Approach 2:
The protrusions extend in multiple directions from the rotor surface, creating three-dimensional mixing paths within the limited clearance space. This multi-dimensional approach to mixing enables effective filler dispersion without requiring increased mixer size or clearance.
3Productivity
If monomer solution and catalyst solution are mixed immediately before reaction, then polymerization reaction is initiated, but homogeneous mixing across wide flow rate ratios is difficult to achieve
Solution Approach 1:
The rotor protrusions create periodic flow disturbances and recirculation zones as liquid formulations pass through the mixing chamber. This periodic action ensures thorough mixing and homogeneous distribution of catalyst throughout the monomer solution before polymerization initiates, even at high flow rates.
Solution Approach 2:
The design replaces complex multi-component mechanical mixing systems with a simpler rotor-protrusion mechanism that achieves homogeneous mixing through optimized fluid dynamics. The protrusions generate sufficient shear and turbulent mixing forces to ensure uniform catalyst distribution without requiring elaborate mechanical mixing arrangements.
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 method enables homogeneous mixing of liquid formulations with wide flow rate ratios and maintains low temperatures, thereby improving the stability and pot life of the polymerization-reactive liquid formulation.
Implementation Method 1
a mixing rotor including a cylindrical rotor body which is accommodated inside the mixing chamber to be rotatable around the central axis of the mixing chamber... a plurality of protrusions which is disposed on the circumferential surface of the rotor body to mix the first preparative liquid formulation with the second preparative liquid formulation by rotation of the rotor body
Implementation Method 2
a bearing member attached to the closed end of the mixing chamber to rotatably support the other end of the rotor body
Data Source
AI summary
A mixing head 3 which mixes a first preparative liquid formulation containing a norbornene-based monomer with a second preparative liquid formulation containing a metathesis polymerization catalyst includes a casing 4, a cap 7, and a mixing rotor 6. A plurality of protrusions 622 includes first protrusions 622a having a width in the axial direction of the mixing rotor 6 larger than that in the circumferential direction, and second protrusions 622b having a width in the axial direction of the mixing rotor 6 smaller than that in the circumferential direction. First and second protrusion rows 623a and 623b are alternately arranged, the first protrusion rows 623a being formed of the first protrusions 622a aligned at a predetermined interval, the second protrusion rows 623b being formed of the second protrusions 622b aligned at a predetermined interval.