Multi-Branch Static Mixer Layout for Low-Flow Laminar Mixing
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Solution Overview
Problem
Existing static mixers struggle to efficiently mix small amounts of fluids and/or solids, particularly when flow rates are low and/or intermittent, leading to inefficient and time-consuming homogeneous mixing.
Innovation Solution
A static mixer design featuring a static mixer housing with inlet ports, channels, flow splitters, and T-style junctions, along with a plastic film, to split and rejoin fluid streams efficiently, even at varying flow rates and conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional static mixers with fixed baffles are used, then mixing is effective for continuous high flow rates, but mixing efficiency deteriorates for low and intermittent flow rates
Solution Approach 1:
The patent applies the dynamics principle by making the baffle elements movable rather than fixed. The baffles are designed to move in response to fluid flow, allowing them to adapt their position and orientation to different flow rates and flow patterns. This dynamic adjustment enables the mixer to maintain effective mixing performance across a wide range of operating conditions, from low to high flow rates, and from intermittent to continuous flow.
2Productivity
If high shear rates are used for mixing, then mixing speed is improved, but damage to biological components occurs
Solution Approach 1:
The dynamic baffle design creates adaptive flow patterns that enhance mixing effectiveness without requiring high shear rates. As the baffles move with the flow, they continuously redirect fluid streams and promote intimate contact between mixed components through gentle laminar mixing mechanisms, achieving thorough mixing at low shear rates that preserve biological components.
3Quantity of substance
If conventional static mixers are used for small amounts of fluid, then mixing can occur, but homogeneous mixing requires very long diffusion processes
Solution Approach 1:
The movable baffles in the patent actively engage with small fluid volumes, creating dynamic flow redistribution that enhances mixing efficiency. As the baffles move, they repeatedly split and recombine fluid streams, significantly increasing the interfacial area for mass transfer and reducing the diffusion path length. This dynamic mixing action achieves homogeneous mixing of small fluid amounts in a compact mixer with short residence time.
Data Source
AI summary
A static mixer, comprising a static mixer housing, having an inlet port for receiving a fluid, a channel in fluid communication with the inlet port, a raised rib along a perimeter of the channel, a flow splitter for splitting the fluid into a first stream and a second stream within channels, a second flow splitter for splitting the first stream into a third stream and a fourth stream within channels and a third flow splitter for splitting the second stream into a fifth stream and a sixth stream within channels, a first T-style junction for rejoining and mixing the third stream and the fourth stream within a channel, a second T-style junction for rejoining and mixing the fifth stream and the sixth stream within a channel, and a third T-style junction for rejoining and mixing the streams; and a plastic film, the plastic film sealed to the raised rib, forming a static mixer capable of mixing the fluid while remaining in a state of laminar flow.