Modular Static Mixer for Additive Manufacturing
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Solution Overview
Problem
The manufacturing of static mixing elements is time-consuming, complicated, and costly, and requires significant adjustments for varying mixing requirements and pressures, which complicates the manufacturing process.
Innovation Solution
A modular static mixer design featuring a housing with a mixing element composed of crisscrossing blade disk pairs, where each blade disk has parallel and spaced blades, allowing for adjustable and stackable modules that can be easily assembled to accommodate different lengths and mixing efficiencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mixing elements with multiple blade sets are used, then mixing efficiency is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The mixing element is divided into multiple identical modular units that can be manufactured separately and then assembled. Each module contains a simplified blade set configuration, and multiple modules are connected in series to form the complete mixing element. This segmentation allows for easier manufacturing of individual components while maintaining the overall mixing efficiency through the combined action of multiple modules.
2Reliability
If traditional mixing elements with multiple blade sets are used, then mixing efficiency is improved, but manufacturing time increases
Solution Approach 1:
By dividing the mixing element into standardized modular units, each module can be manufactured using efficient additive manufacturing processes and then rapidly assembled. The modular design eliminates the need for complex one-piece manufacturing, significantly reducing total manufacturing time while maintaining mixing performance through the series arrangement of multiple simple modules.
3Reliability
If mixing element design is adjusted for particular mixing requirements, then mixing performance is optimized, but manufacturing process complexity increases
Solution Approach 1:
The mixing element is designed with adjustable parameters such as the number of modules, blade angle, and spacing that can be modified to optimize performance for different mixing requirements. The modular architecture allows these parameters to be adjusted by simply changing the configuration or number of identical modules rather than redesigning the entire mixing element, thereby maintaining manufacturing simplicity while optimizing performance.
4Reliability
If complex mixing element designs are used, then mixing efficiency is improved, but production cost increases
Solution Approach 1:
The mixing element is segmented into multiple identical modules that can be manufactured using cost-effective additive manufacturing processes. The standardization of modules allows for economies of scale in production, and the simplified design of each individual module reduces manufacturing costs compared to producing a single complex mixing element. The overall mixing efficiency is maintained through the series arrangement of multiple simple modules.
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 design simplifies the manufacturing process by enabling additive manufacturing without excessive support material and allows for flexible adjustments to accommodate various mixing requirements, reducing production costs and time while maintaining effective fluid blending.
Implementation Method 1
The mixing element may create one or a series of tortuous pathways particularly adapted to induce shear stresses in the fluid as the fluid passes through the conduit
Data Source
AI summary
A static mixer may include a housing having an inlet and an outlet. The static mixer may also include a mixing element arranged within the housing. The mixing element may include a plurality of blade disk pairs arranged in crisscrossing fashion, each blade disk, of the pairs of blade disks, comprising a plurality of parallel extending and spaced apart blades. In some examples, a blade disk may include a link connecting the end of each of the plurality of parallel extending and spaced apart blades. In some examples, the link may be a ring base. In other examples, the link may be a propped tie. Alternatively or additionally, a support perch may be provided for supporting a ring base of an adjoining module.