Multi-Level Stirring Element for Agitators
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Solution Overview
Problem
Existing agitators face challenges in achieving high-speed operation without compromising mixing efficiency, leading to air intake, foam formation, shear forces, and heating issues, especially when handling sensitive materials like paints, ceramics, and biochemical products, which require gentle stirring and low energy consumption.
Innovation Solution
The agitator design features cups arranged on different levels perpendicular to the shaft, allowing for higher speeds and increased power input while maintaining effective mixing, with each cup having a cone shape and an inlet larger than the outlet, and being connected via support arms to a hub or shaft, enabling efficient mixing at both high and low speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high rotational speeds are used to achieve effective mixing, then mixing efficiency is improved, but air intake and foaming occur
Solution Approach 1:
The patent transitions from conventional planar cup arrangement to a three-dimensional multi-level configuration where cups are distributed along the axial direction of the shaft. This spatial redistribution allows the mixing system to operate effectively at higher rotational speeds without generating excessive air intake and foaming, as the multi-level arrangement distributes the mixing action across different heights rather than concentrating it in a single plane.
Solution Approach 2:
The mixing system is divided into multiple independent cup elements arranged at different levels along the shaft. Each cup operates semi-independently, creating localized mixing zones that prevent bulk air entrainment and foaming while maintaining high mixing efficiency. The segmentation allows the system to achieve effective mixing without the harmful effects associated with high-speed operation of conventional single-plane agitators.
2Productivity
If high rotational speeds are used to achieve effective mixing, then mixing efficiency is improved, but shear forces damage sensitive mixtures
Solution Approach 1:
By distributing cups along the axial dimension rather than arranging them in a single plane, the system achieves effective mixing at higher speeds without creating excessive shear forces. The multi-level configuration distributes shear stress across different axial positions, preventing localized high-shear zones that would damage sensitive mixtures while maintaining overall mixing efficiency.
Solution Approach 2:
Each cup in the multi-level arrangement creates localized mixing zones with controlled shear characteristics. The conical geometry of individual cups generates gentle flow patterns suitable for sensitive materials, while the multi-level distribution ensures comprehensive mixing without requiring excessively high rotational speeds that would generate damaging shear forces throughout the entire mixture.
3Productivity
If high rotational speeds are used to achieve effective mixing, then mixing efficiency is improved, but heating of the mixture occurs
Solution Approach 1:
The multi-level cup arrangement distributes mixing action across different axial positions, allowing effective mixing to be achieved with moderate rotational speeds. This prevents the excessive heat generation that would occur with high-speed operation of conventional single-plane agitators, thereby maintaining temperature control for heat-sensitive mixtures while still achieving thorough mixing.
Solution Approach 2:
The mixing process is segmented into multiple localized zones created by individual cups at different levels. Each zone contributes to overall mixing efficiency without requiring high rotational speeds, thereby minimizing cumulative heat generation across the entire mixing process while maintaining effective homogenization.
4Ease of manufacture
If cups are arranged in a common plane perpendicular to the shaft, then manufacturing and assembly are simplified, but rotational speed is limited without reducing stirring effect
Solution Approach 1:
The patent extends the cup arrangement from a two-dimensional planar configuration to a three-dimensional multi-level structure along the axial direction. This spatial extension enables the system to operate at higher rotational speeds while maintaining effective stirring, as the multi-level arrangement distributes the mixing action across different heights, preventing flow disturbances that would limit speed in conventional planar designs.
5Ease of manufacture
If conventional agitator design is used, then manufacturing is simplified, but dead zones form reducing mixing completeness
Solution Approach 1:
By distributing cups along the axial dimension in a multi-level configuration, the system eliminates dead zones that form in conventional single-plane designs. The multi-level arrangement ensures comprehensive fluid circulation throughout the entire mixing volume, including regions near the top and bottom surfaces, thereby achieving complete mixing without significantly complicating the manufacturing of individual cup elements.
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 allows for efficient mixing with reduced energy consumption and prevents flow disturbances, enabling complete coverage and thorough mixing of materials, even at higher speeds, while minimizing the formation of dead zones and maintaining the integrity of temperature-sensitive substances.
Implementation Method 1
the cross-section of the conical pipe section narrows in the opposite direction of rotation, i.e., in the direction of flow. The inlet opening for the flowing material is therefore larger than the outlet opening. Furthermore, the longitudinal axis of the conical pipe section is angled downwards in the direction of rotation.
Implementation Method 2
The low speed of the agitators causes counter-currents to form in the mixture, promoting the mixing effect.
Implementation Method 3
This design allows for efficient mixing with reduced energy consumption and prevents flow disturbances, enabling complete coverage and thorough mixing of materials
Data Source
AI summary
The present invention relates to a stirring element for an agitator for mixing and/or homogenizing flowable media, comprising at least two stirring bodies (2) having an inlet opening and an outlet opening for the flowable medium, wherein the inlet opening (5) is larger than the outlet opening (6), characterized in that the stirring bodies (2) belonging to the stirring element (1) are arranged on different planes normal (perpendicular) to the agitator shaft, each having a defined distance from the other in the axial direction.